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Raypak 850 Electric Heater User Manual

1. iL I Fig 10 Gas Supply Connection 16 CAUTION Do not use Teflon tape on gas line pipe thread A pipe compound rated for use with natural and propane gases is recommended Apply sparingly only on male pipe ends leaving the two end threads bare CAUTION Support gas supply piping with hangers not by the heater or its accessories Make sure the gas piping is protected from physical damage and freezing where required Gas Supply Pressure A minimum of 4 0 in WC and a maximum of 10 5 in WC upstream gas pressure is required under load and no load conditions for natural gas A minimum of 4 0 in WC and a maximum of 13 0 in WC is required for propane gas The gas pressure regulator s supplied on the heater is for low pressure service If upstream pressure exceeds these values an intermediate gas pressure regulator of the lockup type must be installed When connecting additional gas utilization equipment to the gas piping system the existing piping must be checked to determine if it has adequate capacity for the combined load The gas valve pressure regulator on the heater is nominally preset as noted in Table 1 During normal operation carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 0 and 9 5 for propane gas Carbon monoxide should be 150 ppm Manifold Pre
2. 2 Cascade Pwr XXX 0 100 Cascade demand Present OXXXXXXX 0 8 Heaters present in cascade 3 Cascade Sys XXX F 13 248 Cascade System temperature Cascade Set 160 F 50 190 F Cascade setpoint 4 Boiler 0 XXX 0 100 Heater demand Boiler 1 XXX 0 100 Heater demand 5 Boiler 2 XXX 0 100 Heater demand Boiler 3 XXX 0 100 Heater demand 6 Boiler 4 XXX 0 100 Heater demand Boiler 5 XXX 0 100 Heater demand 7 Boiler 6 XXX 0 100 Heater demand Boiler 7 XXX 0 100 Heater demand Installer Menu Items Screen No Default Information Displayed Range Description 1 Operational Mode Operational mode of the controller Hydronic No DHW Hydronic w DHW or Combi N A for XFyre 2 DHW Combi Max if active Not used for XFyre 149 F 104 149 F Setting 3 DHW Tank Max if active Maximum User Setting for DHW tank temperature 180 F 95 185 F Setting 4 Offset if active Combi N A mode only display temperature offset 36 F 1 45 F Setting 5 DHW Diff Subtractive DHW differential 5 F 1 18 F Setting 6 DHW Pump Delay DHW pump delay timing 0 min 0 10 minutes Setting 1 Outdoor Cutoff Cutoff temperature for outdoor temperature reset systems 68 F 41 122 F Setting 8 Reset Min Out Minimum outdoor design temperature 5 F 49 32 F Setting 9 Reset Max Temp Maximum outdoor reset setpoint temperature 190 F 77 190 F Setting 10 Reset Max Out Maximum outdoor design temperature 68 F 32 95 F Setting
3. GROUND GROUND 3 stuTRAL 2 12 BLACK 1 901950 REV2 Fig 11a Wiring Electrical Connections 17 may power up to two pumps directly 1 hp max boiler pump 3 A max DHW pump and may control a third system pump depending on the configuration of the controller and the installation requirements Install a circuit breaker sized sufficiently for both the heater and the pump s DHW pumps larger than 1 4 hp or 3 A must use a separate power supply and run the power through an external field supplied pump contactor Use appropriately sized wire as defined by NEC CSA and or local codes All primary wiring should be 125 of minimum rating If any of the original wire as supplied with the heater must be replaced it must be replaced with 105 C wire or its equivalent All 120 VAC field wiring connections to the XFyre heater are made inside the rear wiring box as shown in Fig 11a Power to the XFyre heater should be con nected to terminals 1 2 and 3 as shown in Fig 11a Low voltage wiring is connected to the field wiring board at the front of the unit Sensors Thermostat TT Ic SYSTEM PUMP dut o ex agerem o CT NO BOILER PUMP HOT GROUND 2 GROUND 3 2 BLACK lion 1 P N 901950 REV2 Fig 11b Wiring Electrical Connections Cascade Master conta
4. 37 Installer Menu Items continued Screen No Default Information Displayed Range Description 11 Reset Min Temp Minimum outdoor reset setpoint temperature 95 F 32 190 F Setting 12 Hydronic Min Temp Hydronic minimum temperature 90 F 32 190 F Setting 13 Hyd Pump Delay Heater pump delay timing 0 0 10 minutes Setting 14 DHW Priority DHW priority timing 30m 0 60 minutes Setting 15 Cascade Addr Heater cascade address 0 for master 1 7 for followers 0 0 8 Heater address setting do not use address 8 16 0 10V 0 10V input configuration DHW Thermistor Direct DHW Thermistor OFF Boosterboard 17 0 10 Mode selection for 0 10 Direct input operation Temperature Temperature Setpoint or Fan Speed Firing rate 18 Step Mod Enable or disable step modulation ON ON OFF Setting 19 Temp to Indirect Heater output setpoint for indirect operation 180 F 119 190 F Setting 20 WPS Input Factory configured do not change Flow Switch Low Water Cutoff Flow Switch Water Pressure None 21 Error Outd Sensor Enable outdoor sensor error reporting OFF ON OFF Setting 22 Max Fan Speed Allows reduction of maximum input rate 100 50 100 Setting 23 Cascade Config Cascade or non cascade operation OFF VIS 3 All 926 OFF All 926 for single or multi heater cascade 24 Cascade Rotation Le
5. Fig 17 XFyre Cascade System Wiring 3 Create a hole to route the communication cables addressed The communication bus jacks on the through where the dimples are in the side of the customer connection panel are interchangeable cabinet see Fig 15 or route the wires to the rear so you can use either one or both in any order to junction box and out of the cabinet connect the cable to If you have connected the boilers to each other properly two of the boilers 4 Connect the boilers in a daisy chain configuration will have one open connection port on them as shown in Fig 17 above It is best to wire the boilers using the shortest wire runs rather than try ing to wire them in the order that they are 21
6. NOTE The onboard fault history only records faults that lock out the system FXX faults XFyre Fault Text OUTDOOR SENSOR FOU Inspect wiring from outside sensor for damage or shorted connections repairing as necessary Measure Displays only if Screen 21 of the resistance of outdoor sensor and compare to resistance chart on page 48 If not within range chart Installer Menu is ON shorted or open replace sensor Inspect power wiring to boiler and repair as necessary If connected to line voltage notify power compa ny If connected to alternate power source such as generator or inverter make sure line voltage frequency supplied by the device is 60 Hz LINE VOLTAGE E19 1 Ensure that the flue is not blocked 2 Check the switch wiring by applying a jumper in place of the switch If the code clears with the jumper in place REPLACE the flue switch and connect the wires to the new switch BEFORE running unit WARNING Do not use jumper to remedy this error Faulty switch MUST be replaced Failure to do so could result in serious injury or death BLOCKED VENT FLU 1 Check boiler feed water system to be sure it is supplying make up water to boiler system LOW WATER LEVEL LEO 2 Make sure all air is bled from the system 3 Check for leaks in boiler and system piping and repair as necessary 4 Inspect low level switch and wiring for damage and repair as necessary 1 Check line voltage Must be between 100 128 VAC 2 I
7. y uen Connect the boiler pump to the terminals marked BOILER PUMP 6 BOILER PUMP INPUT 5 and GROUND 4 CASCADE BUS ZONE CONTROL ONLY THERMOSTAT 05 Connect the system pipe sensor to the terminals T marked SYS SENSOR as shown in Fig 18 2 0 10 OUTDOOR o THERMOSTAT F Connect the outdoor sensor if used to the termi SENSOR _ THERMOSTAT p e OUTDOOR SEN E nals marked OUTDOOR SEN OUTDOOR SEN A SYS SENSOR 1 H SYSTEM Y Connect the signal to start the system to the termi SENSOR g nals marked THERMOSTAT ES 4 NOTE This signal can come from room A amp thermostat or a dry contact closure No power of any eoero all voltage should be fed into either of these terminals PUMP OPTIONAL _ Boner do 12 ZJN ib z g BOILER GND 5 BOILER BOILER NEUT 5 FUME BOILER HOT 5 V GROUND d g O CAT3 CAT 5 CONNECTION POINTS NEUTRAL A 120 vons 5 l BLACK HOT E on za 9 e 5 CASCADE BUS ZONE CONTROL ONLY GREEN GROUND WHITE NEUTRAL BLACK HOT 0 10V A 5 0 10V LNE ee O THERMOSTAT D 5 THERMOSTAT ourbooR May be configured as DHW SENSOR for Pi MN A single boiler Cascade with Indirect DHW SENSOR 9 Fig 18 Cascade Master 8r LIGHT LIGHT Fa Cascade Master Pump and PME 8 Sensor Wiring LOCKOUT LOCKOUT 2
8. 13 To perform hydrostatic test 1 Connect fill water supply With bleed valve open fill heater with water When water flows from bleed valve shut off water Close bleed valve Carefully fill the rest of the system making sure to eliminate any entrapped air by using high point vents Close feed valve Test at standard operating pressure for at least 24 hours 2 Make sure constant gauge pressure has been maintained throughout test 3 Check for leaks Repair if found Hydronic Heating Pump Selection In order to ensure proper performance of your heater system you must install a correctly sized pump Ray pak recommends designing for a AT within the range of 20 F to 40 F 5 C to 20 C See Table G for accept able flow rates for each model AT is the temperature difference between the inlet and outlet water when the heater is firing at full rate Feedwater Regulator Raypak recommends that a feedwater regulator be in stalled and set at 12 psi minimum pressure at the highest point of the system Install a check valve or back flow device upstream of the regulator with a manual shut off valve as required by local codes Piping All high points should be vented A heater installed above radiation level must be provided with a low wa ter cut off device sales order option F 10 This heater when used in connection with a refrigeration system must be installed so that the chilled medium is piped in parallel with the heat
9. A dedicated circuit breaker should be provided and sized for the heater and all pumps powered through the heater NOTE Current draw noted on rating plate does not include pump current Turn off all power to the heater Verify that power has been turned off by testing with a multi meter prior to working with any electrical connections or components Observe proper wire colors while making electri cal connections Many electronic controls are polarity sensitive Components damaged by im proper electrical installation are not covered by warranty Provide overload protection and a disconnect means for equipment serviceability as required by local and state code Install heater controls thermostats or building management systems in accordance with the applicable manufacturers instructions Conduit should not be used as the earth ground NOTE A grounding electrode conductor shall be used to connect the equipment grounding conductors the equipment enclosures and the grounded service conductor to the grounding electrode Field Wiring Connections DANGER SHOCK HAZARD CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause im proper and dangerous operation Verify proper operation after servicing Make sure electrical power to the heater is discon nected to avoid potential serious injury or damage to components DIMPLES FOR ALTERNATE LOW VOLTAGE WIRE ROUT
10. MODELS 300 850 SCOPE Raypak Inc Raypak warrants to the original owner that all parts of this heater which are actually manufactured by Raypak will be free from failure under normal use and service for the specified warranty periods and subject to the conditions set forth in this Warranty Labor charges and other costs for parts removal or reinstallation shipping and transportation are not covered by this Warranty but are the owner s responsibility HEAT EXCHANGER WARRANTY Space Heating Closed Loop System Ten 10 year limited warranty from date of heater installation This warranty applies only to boilers utilized in closed loop heating systems and hot water supply boilers that have been properly installed based upon manufacturer s installation instructions Year of Claim 0 5 6 7 8 9 Percentage to be paid by purchaser 0 20 40 60 80 Thermal Shock Warranty Twenty 20 years from date of heater installation against Thermal Shock excluded however if caused by heater operation at large changes exceeding 150 F between the water temperature at intake and heater temperature or operating at heater temperatures exceeding 215 F ANY OTHER PART MANUFACTURED BY RAYPAK One 1 year warranty from date of heater installation or eighteen 18 months from date of factory shipment based on Raypak s records whichever comes first SATISFACTORY PROOF OF INSTALLATION DATE SUCH AS INSTALLER INVOICE IS REQUIRED THIS WARRANTY W
11. Service clearances less than the minimum may require removal of the heater to service either the heat exchanger or the burner components In either case the heater must be installed in a manner that will enable the heater to be serviced without removing any structure around the heater Outdoor Installations These heaters are design certified for outdoor installa tion Heaters must not be installed under an overhang unless clearances are in accordance with local instal lation codes and the requirements of the gas supplier Three sides must be open in the area under the over hang Roof water drainage must be diverted away from heaters installed under overhangs TOP_VIEW 24 SERVICE j CLEARANCE FRONT VIEW 24 1 SERVICE CLEARANCE VERTICAL CLEARANCE ALL INSTALLATIONS Venting not shown for clarity Heater must be vented per instructions in this manual Fig 4 Minimum Clearances from Combustible Surfaces Indoor and Outdoor Installations Recommended Service Clearances Min Clearances from Combustible Surfaces 24 Unobstructed Table E Clearances Outdoor Installations Combustion and Ventilation Air NOTE Use of this boiler in construction areas where fine particulate matter such as concrete or dry wall dust is present may result in damage to the boiler that is not covered by the warranty If operated in a construction environment a clean source of combustion air must be provide
12. date of installation and description of the problem The installer must then notify his Raypak distributor for instructions regarding the claim either is not available contact Service Manager Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 or call 805 278 5300 In all cases proper authorization must first be received from Raypak before replacement of any part EXCLUSIVE WARRANTY LIMITATION OF LIABILITY This is the only warranty given by Raypak No one is authorized to make any other warranties on Raypak s behalf THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE RAYPAK S SOLE LIABILITY AND THE SOLE REMEDY AGAINST RAYPAK WITH RESPECT TO DEFECTIVE PARTS SHALL BE AS PROVIDED IN THIS WARRANTY IT IS AGREED THAT RAYPAK SHALL HAVE NO LIABILITY WHETHER UNDER THIS WARRANTY OR IN CONTRACT TORT NEGLIGENCE OR OTHERWISE FOR ANY SPECIAL CONSEQUENTIAL OR INCIDENTAL DAMAGE INCLUDING DAMAGE FROM WATER LEAKAGE Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages So the above limitation or exclusion may not apply to you This Limited Warranty gives you specific legal rights You may also have other rights which may vary from state to state We suggest that you complete the information below and retain this certificate in the event warranty s
13. 1 100 mm per kW of total input rat ing of all equipment in the enclosure One permanent opening commencing within 12 in 305 mm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 25 mm from the sides and back and 6 in 152 mm from the front of the appliance The opening shall directly communicate with the out doors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of a 1 2 per 3 000 BTUH 740 mm per kW of the total input rating of all equipment located in the enclosure and b Notless than the sum of the areas of all vent connectors in the confined space and terminated 18 in 450 mm from the floor but not near piping This air supply opening require ment shall be in addition to the air opening for ventilation air required in 1 above WARNING Care must be taken to ensure that the equipment room is not under negative pressure conditions 3 For heaters when air supply is provided by natural air flow from outdoors for a power burner and there is no draft regulator drafthood or similar flue gas dilution device installed in the same space in addition to the opening for ventilation air required in 1 there shall be a permanent air supply open ing s having a total cross sectional area of not less than 1 in 2 for each 30 000 BTUH 74 mm per
14. Confirm that the proper start up procedures were followed Inspect burner to verify flame Test safety controls If boiler is equipped with a low water cut off or additional safety controls test for operation as outlined by manufacturer Burner should be operating and should go off when con trols are tested When safety devices are restored burners should re ignite after pre purge time delay Check to see that the high limit control is set above the design temperature requirements of the system For multiple zones Check to make sure the flow is adjusted as required in each zone Check that the boiler is cycled with the thermostat Raise the setting on the thermostat to the highest setting and verify that the boiler goes through the normal start up cycle Reduce to the lowest set ting and verify that the boiler goes off Observe several operating cycles for proper oper ation Set the boiler thermostat to desired temperature Review all instructions shipped with this boiler with owner or maintenance person return to envelope and give to owner or place the instructions inside front panel on boiler 44 OPERATION Lighting Instructions 1 10 Before lighting make sure you have read all of the safety information in this manual Set the thermostat to the lowest setting Turn off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do n
15. are found on the heater rating plate located on the upper rear jacket panel of the heater The model number will have the form H7 850 or similar depend ing on the heater size and configuration The letter s in the first group of characters identifies the application H Hydronic Heating W Hot Water The number which follows identifies the firing mode 7 electronic modulation The second group of characters identifies the size of the heater three numbers representing the approximate MBTUH input and where applicable a letter indicating the manufacturing series Ratings and Certifications Standards ANSI 721 13 CSA 4 9 latest edition Gas Fired Hot Water Boilers 3 1 latest edition Industrial Commercial Gas Fired Package Boilers e SCAQMD Rule 1146 2 and All Raypak heaters are National Board Registered and design certified and tested by the Canadian Standards Association CSA for the U S and Canada Each heater is constructed in accordance with Section IV of the American Society of Mechanical Engineers ASME Heater Pressure Vessel Code and bears the ASME stamp This heater also complies with the latest edition of the ASHRAE 90 1 Standard WARNING Altering any Raypak pressure vessel by installing replacement heat exchangers or any ASME parts not manufactured and or approved by Raypak will instantly void the ASME and CSA ratings of the vessel and any Raypak warranty on the vessel Alteri
16. cause other safety control damage or failure Attach Manometers to Measure Pressures 1 Turn off main gas valve 2 Attach 1 12 scale manometer to an upstream bleedle valve on the gas supply pipe to the boiler Measure point A in Fig 35 3 Attach 1 12 scale manometer to the manifold pressure tap located downstream of the valve Measure point D in Fig 35 4 Attach 1 12 scale manometer to the tapping on the filter box Pull black cap from air pressure switch tee and connect the manometer NOTE Retain caps for reinstallation later MODEL 300 VALVE USES SAME POINTS A amp DAS MODEL 500 Fig 35 Gas Pressure Measurement Locations 42 Check Gas Supply Pressure 1 Slowly turn on main gas shut off valve 2 Read the gas supply pressure from the manome ter minimum supply pressure for natural gas is 4 0 in WC recommended supply is 7 0 in WC mini mum supply pressure for propane gas is 4 0 in WC recommended supply is 11 0 in WC dynam ic readings full fire input If the gas pressure is greater than 14 0 in WC turn off the main gas shut off valve Start Up Turn power on Turn on the boiler approximately 5 seconds after the blower starts the igniter should start to spark observable through the observation port located at the front bottom of the boiler and the gas valve will open Look into the sight glass located at the bottom of the front panel to check igniter ope
17. corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly 3 ft 91 cm within a height 15 ft above the me ter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance Clearance to mechanical air supply inlet Clearance above paved sidewalk or paved driveway located on public property 6 ft 1 83m 4 ft 1 2m below or to side of opening 1 ft 30 cm 3 ft 91 cm above opening 3 ft 91 cm above if within 6 ft 1 83m 10 ft 3m horizontally 7 ft 2 13m t 7 ft 2 13m Clearance under veranda porch deck or balcony 12 in 30 cm TT In accordance with the current ANSI 7223 1 54 National Fuel Gas Code In accordance with the current CAN CGA B149 Installation Codes Vent terminal shall not terminate directly above sidewalk or paved driveway located between 2 single family dwellings that serves both dwellings Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor and top of terminal and underside of veranda porch deck or balcony is greater than 1 ft 30cm Clearances in accordance with local installation codes and the requirements of the gas supplier Table F Vent Air Inlet Termination Clearances 10 Combustion Filter This heater is supplied with an integra
18. default setting is 160 If changes are necessary follow Adjusting The XFyre Setpoint in this section On the initial start up of units with gas pressure switches the control user interface will display flue gas press This is a low gas pressure switch lock out from the factory installed low gas pres sure switch You will also see a yellow LED illuminated under the cover of the low gas pres sure switch Once the gas is turned on reset the gas pressure switch by FIRMLY pressing on top of the plastic cover over the red reset button The yellow LED will go out after the switch has been reset Press and hold the ESC RESET key on the control panel for about 4 seconds to begin normal operation Set the thermostat to the desired setting 5 If the appliance fails to start refer to the Troubleshooting section in the back of this manu al NOTE Before you can change the temperature from the factory setting of 160 degrees you must make sure none of the thermostats are calling for heat The controller will not memorize a program 34 setting while in a heating cycle User Menu The user menu consists of several items that can be adjusted To access the user menu press and hold the ENTER MENU key for 5 seconds Using the UP and DOWN and LEFT and RIGHT arrow keys enter 600 then press ENTER MENU Scroll through the list of adjustable items by pressing the LEFT or RIGHT arrow keys Once the desired item is displayed pr
19. electrode and flame rectification probe and combustion blower Remove the 4 screws on the aluminum 9 NPT connector on the right side of the gas valve Disconnect the wiring connected to the com bustion blower motor f Remove the 6 10mm nuts from the burner plate assembly Pull the entire burner plate assembly with blower still attached towards you while removing or pushing aside any wiring to allow the removal of the assembly 2 Using a spray bottle filled with the recommended product RYDLYME or CLR spray liberally on the coils making sure the solution penetrates and fun nels down through the condensate system If the condensate system is blocked let the chemical penetrate for at least 15 minutes or until it drains Use the nylon stainless steel or brass brush do not use steel to scrub coils to remove any buildup then vacuum the debris from the coils Be sure to fol low the precautions listed for working with ceramic fibers 4 Spray the coils with clear water making sure to con fine the spray to the area being cleaned Try to avoid getting the back ceramic wall of the unit wet Flush the combustion chamber with fresh water until clear water runs from the condensate drain At this point the XFyre should be ready to be re assembled a Inspect gaskets b Re install the burner assembly APPENDIX Inside Air Contamination Combustion air can be contaminated by certain vapors in the a
20. flow rates for soft and medium water Hard water must be softened for direct heating with the XFyre Water hardness is expressed in grains per gallon wrar o Mo NM No ft gpm aP ft ft gpm aP ft AT gem aP ft AT afo pe Peo 8 Notes Basis for minimum flow is AT Basis for maximum flow is gpm Table G Heater Rates of Flow and Pressure Drops 1 FROM SYSTEM 2 Fig 9 Single Domestic Hot Water Heater and Storage Tank 3 4 TO SYSTEM a BOILER 1 MASTER BOLER 2 FOLLOWER 1 2 Fig 10 Multiple Boilers Reverse Return Primary Secondary Piping with Indirect DHW Model Soft 0 4 grains per gallon NOTE If local codes require a vacuum relief valve acquire one locally and install per valve manufacturer s instructions Potable Water and Space Heating CAUTION When this heater is used for both potable water and space heating observe the following to ensure proper operation All piping materials and components connected to the water heater for the space heating application shall be suitable for use with potable water Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water used for space heating If the heater will be used to supply potable water it
21. kW of total rated input of the burner s and the location of the opening s shall not interfere with the intended purpose of the opening s for ventila tion air referred to in 1 This opening s can be ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof WARNING Do not use the one permanent The duct is preferred to be straight down 18 in opening method if the equipment room is under 450 mm from the floor but not near piping negative pressure conditions 4 Refer to the B149 Installation Code for additional Canadian Installations information Water Piping CAUTION All combustion air must be drawn from the air outside of the building the mechanical equip ment room must communicate directly with the General outdoors The heater should be located so that any water leaks 1 Ventilation of the space occupied by the heater will not cause damage to the adjacent area or struc shall be provided by an opening s for ventilation tures air at the highest practical point communicating with the outdoors The total cross sectional area of such an opening s shall be at least 10 of the area required in 2 and 3 below but in no case shall the cross sectional area be less than 10 in 65 cm2 and water pump selection The pump must be interlocked with the boiler to prevent heater operation without water circulati
22. observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vent ed gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a min imum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment Th
23. pipe for c ul Support of Vent Stack From Outside Building Direct Venting The weight of the vent stack or chimney must not rest on the heater vent connection Support must be pro vided in compliance with applicable codes The vent should also be installed to maintain proper clearances from combustible materials Use insulated vent pipe spacers where the vent passes through combustible roofs and walls When using PVC or CPVC venting on models 300 and 500 insert the vent pipe 3 5 inches into the unit and provide rigid support to the vent so that it will not shift laterally Vent Terminal Location 1 Condensate can freeze on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice Give special attention to the location of the vent termination to avoid possibility of property dam age or personal injury Gases may form a white vapor plume in winter The plume could obstruct a window view if the ter mination is installed near windows Prevailing winds in combination with below freez ing temperatures can cause freezing of condensate and water ice build up on buildings plants or roofs Canada Only ULC ee PVC and CPVC Stainless Steel AL29 4C ANSI ASTM D1785 Sch 40 PVC ANSI ASTM F441 Sch 40 CPVC Galvanized Steel PVC ABS CPVC The bott
24. plants e beauty shops refrigeration repair shops e photo processing plants e auto body shops plastic manufacturing plants furniture refinishing areas and establishments new building construction remodeling areas Open pit skimmers Check for areas and products listed above before in stalling heater If found remove products permanently OR install TruSeal direct vent Important Instructions for the Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of through the wall vented gas appliances as follows a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall
25. shall not be connected to any heating system or components previously used with a non potable water heating appliance When the system requires water for space heating at temperatures higher than 140 F 60 C a means such as a mixing valve shall be installed to temper the water in order to reduce scald hazard potential Medium 5 15 grains per gallon No at opm ae wr sat at am se wre sc pote pep oa s m fis a ao ppm prp fs 9 fa 59 2 sw 2 Temperature rise F AP Pressure drop through heat exchanger ft SHL System head loss ft based on heater and tank placed no more than 5 ft apart and equivalent length of 25 ft of tubing gpm Gallons per minute flow rate MTS Minimum tubing size CAUTION For scale free operation with Medium water 5 15 grains per gallon of total hardness the operating control must NOT be set higher than 130 F For higher than 130 F operation or Hard water gt 16 grains per gallon of total hardness a water sof tener treatment system must be utilized Table H Domestic Water Heater Flow Rate Requirements 15 Gas Supply DANGER Make sure the gas on which the heater will operate is the same type as specified on the rat ing plate Gas piping must have a sediment trap ahead of the heater gas controls and a manual shut off valve lo cated outside the heater jacket It is recommended that a union be installed
26. the UP arrow key and ENTER MENU key simultaneously for 1 sec ond Set the fan speed using the UP and DOWN arrow keys Manifold Check 1 Check manifold gas pressure at the manifold pres sure tap connection D in Fig 35 This pressure should read per the values in Table S for natural and propane gas If the pressure reading differs by more than x 0 2 in WC STOP Call the factory for directions on what to do next Air Pressure Setting Setting in WC Tolerance 02 WC t02in WC 02 WC Table XFyre Intake Air Pressure Settings High Fire 5000 3000 1500 7600 3000 1750 5500 3000 1500 Table XFyre Fan Speed Settings Manifold Pressure in WC Natural Gas Propane Gas Lun Lew High tow Model No NOTE Manifold pressures should be 0 3 in WC Table S XFyre Manifold Pressure Settings CAUTION Special manifold and air settings may be required 43 Finishing 1 Record all data on the Start up Checklist located at the back of this manual 2 Disconnect the manometers and reconnect the cap on the air intake and reinsert or close the seal ing screws into the bleedle valves 3 Start up is complete and the boiler should be oper ating properly Safety Inspection 1 Check all thermostats and high limit settings 2 During the following safety checks leave manome ters hooked up check and record 3 If other gas fired appliances in the room are o
27. there is less than a 50 F rise from the return thermistor to the supply thermistor 3 Check thermistor reading on supply thermistor Replace switch if faulty 4 If this is a new installation disconnect the two TT wires from the zone control and connect the wires together Depress the ESC RESET button If the fault clears the problem is outside the boiler HIGH TEMPERATURE F00 46 FLUE GAS PRESS F01 SUPPLY THERMISTR F02 RETURN THERMISTR F03 SUPPLY HIGH F05 NO FLAME F09 FLAME FAILURE F10 FLAME WHEN OFF F11 FAN SPEED ERROR F13 CONDENSATE FULL F20 PROGRAMMED PP MEMORY ERROR F31 1 If the boiler is equipped with High and or Low gas pressure switches examine the switch es to see if the yellow LED is illuminated on the switch If so correct the gas supply problem associated with the switch and reset the switch by pressing on the cover of the switch over the red button to reset the switch Pressing the button requires a firm push Push the Reset button on the front panel of the boiler to reset the boiler control 2 If the boiler has a UL353 LWCO check to see if the red LED on the LWCO control box is illuminated If so correct the low water condition and press the reset button on the LWCO control box to reset the LWCO The LED should change to green Press the reset button on the front panel of the boiler to reset the boiler con trol 3 Check the flue for obstructions or any sign of damage especially signs of e
28. to the appliance if serv ice is to be performed 45 TROUBLESHOOTING XFyre Error Codes If any of the sensors detect an abnormal condition or an internal component fails during the operation of the XFyre the display may show an error code This code may either be the result of a temporary condition in which case the display will revert to its normal readout when the condition is corrected or it may be the result of a condition that the controller has evaluated as not safe to restart the unit In this case the unit control will be locked out requiring the maintenance person to manually reset the control by pressing the ESC RESET key for more than 1 second Typically if the display has a code beginning with F followed by 2 numbers the XFyre is locked out If the display has a 3 letter code it is the result of a temporary condition Heater Errors When an error condition occurs the controller will dis play an error code on the display module These error codes and several suggested corrective actions are included in the XFyre Fault Text section on the follow ing page Heater Faults When a fault condition occurs the controller will illuminate the red fault indication light and display a fault code in the format The alarm output will also be activated Most fault conditions will also cause the boiler pump to run in an attempt to cool the unit Note the fault text and refer to the XFyre Fault Text section for an explan
29. tools If the knob will not turn by hand do not try to repair it call a qualified serv ice technician Forced or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water Check around unit for debris and remove com bustible products i e gasoline etc Pre Start up Check 1 Verify the heater is filled with water Check system piping for leaks If found repair immediately 3 Vent air from system Air in system can interfere with water circulation 4 Purge air from gas line to boiler Initial Start up Required tools 1 12 0 12 24 scale U tube manometer 2 6 0 6 12 scale U tube manometer Screwdrivers assorted sizes and shapes 1 Crescent wrench 8 or 10 1 Multi meter Metric Allen wrenches will be required for servicing the gas valve but not during start up NOTE Digital manometers are not recommended Preparation WARNING Do not turn on gas at this time Check Power Supply With multi meter at incoming power check voltage between Hot Common 120 VAC Hot Ground 120 VAC Common Ground lt 1 VAC WARNING Common Ground is gt 1 VAC STOP Contact electrician to correct ground failure Failure to do this may burn out 120V 24V transformer or may
30. zontally from or 1 ft above any door window or gravity air inlet to the building 2 The vent must not be less than 7 ft above grade when located adjacent to public walkways 3 Terminate vent at least 3 ft above any forced air inlet located within 10 ft 4 Vent must terminate at least 4 ft horizontally and in no case above or below unless 4 ft horizontal distance is maintained from electric meters gas meters regulators and relief equipment 5 Terminate vent at least 6 ft away from adjacent walls 6 DO NOT terminate vent closer than 5 ft below roof overhang 7 The vent terminal requires a 12 in vent terminal clearance from the wall 8 Terminate vent at least 1 ft above grade including normal snow line 9 Multiple direct vent installations require a 4 ft clearance between the ends of vent caps located on the same horizontal plane WARNING The Commonwealth of Massachusetts requires that sidewall vented heaters installed in every dwelling building or structure used in whole or in part for residential purposes be installed using special provisions as outlined on page 53 of this manual Installations in Canada Refer to latest edition of the B149 Installation Code A vent shall not terminate 1 Directly above a paved sidewalk or driveway which is located between two single family dwell ings and serves both dwellings 2 Less than 7 ft 2 13 m above a paved sidewalk or paved driveway located on pu
31. 14 14 goo am N S 131 5 5 122 122 amp B amp z Ms 113 B B 104 104 4 E 5 95 E 95 FUNCTION 11 o x 86 2 se a fx 77 2 77 68 E 59 25 50 2 41 P 32 T T T T T T T Pek pg Gn EEG SEN CD eft pompe qe 59 41 24 9 9 27 45 63 81 99 59 41 24 9 9 27 45 63 81 99 5 OUTSIDE TEMPERATURE F OUTSIDE TEMPERATURE F Fig 33 Outdoor Reset Curve Factory Default F g 34 Outdoor Reset Curve Plot Your Curve 39 186291 MOTIL ILAN M 100 201 3cWoss OL 3un1w3 703 WNINYAL OL ono 2 SILON ALANS S 008 00 BAVA SYO nosa in INWA SVO ONY 34078 OL 058 T30OW X04 3 pul NALINI WNINY
32. 1785 Sch 40 PVC ANSI ASTM F441 Sch 40 CPVC Horizontal Vent Height ft Combustion Air Intake Pipe Material Air Inlet Max Length ft Galvanized Steel PVC ABS CPVC Table O Category IV Horizontal Vent amp Horizontal Direct Vent Direct Vent Vertical piis FLUE EXHAUST N INTAKE VENT LLL INSULATED EXHAUST HEATER UNIT CONDENSATE TRAP Fig 24 Direct Vent Vertical CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this boiler Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com bustion products to the outdoors 30 The total length of air supply pipe cannot exceed the distances listed in Table L Each elbow used is equal to 10 ft of straight pipe This will allow installation in any arrangement that does not exceed the lengths shown in Table L The vent cap is not considered in the overall length of the venting system Care must be taken during assembly that all joints are sealed properly and are airtight The vent must be installed to prevent the potential ac cumulation of condensate in the vent pipes It is required that 1 The vent must be installed with a condensate drain as dir
33. 4 Remove the valve and check for obstruction in the valve seat or replace the gas valve 5 Turn the gas on at the service valve after corrective action is taken 6 Check for condensate back up Condensate back up can damage the refractory wall and if the wall falls against the rectifier probe it may conduct the signal to ground giving a false reading 1 Check the combustion air fan wiring 2 Check the 24 VAC signal by measuring from any connected safety to ground A low voltage situation may cause a false error code 3 Replace the combustion air fan 4 Replace the control board 1 Check condensate lines for obstructions 2 Check float switch in condensate reservoir 3 Check wiring from condensate reservoir to control board and repair as necessary Press ESC RESET for at least 1 second Control must be re programmed If programming does not solve problem control must be replaced 47 Sensor Resistance Values Temperature Sensors Water Temperature F Resistance ohms 32550 25340 19870 Outdoor Sensor Water Temperature F Resistance ohms 22 12490 10000 8059 6535 2989 2490 2084 176 1256 m E ay 194 203 NOTE If receiving a NO FLAME 209 fault code check the gap spacing between points on the electrode by holding two quarters together and sliding them through the gap There should be a slight resistance Fig 36 Dir
34. ACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting sys tems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by the Board and the instructions for that system shall include a parts list and detailed installation instructions e A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equip ment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation GAS PRESSURE SUPERVISION The Commonwealth of Massachusetts requires listed high and low gas pressure switches manual reset for any model with a maximum firing input greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 11 d A gas pressure regulator field supplied is required in the gas train ahead of the heater for heaters having input rates greater than 1 000 000 Btu Hr in accordance with 248 CMR 7 04 Figure 3B requirements LIMITED PARTS WARRANTY XFYRE and W
35. AL 80 poral 2105109 926 soe aT ov unos TERT TET Qnin pe T TWNINY TOOT E i 65655656 HOLS 13232 d P ira 35 cx m UD sse Ul sss UI ee Quvog 91313 81 TY wNoudo 2 1 8 O WIRING DIAGRAM NOTE The wiring diagrams in this manual show all standard options Refer to the large wiring diagram provided with your boiler for options installed on your specific unit s START UP Pre Start up Filling System Heating Boilers Fill system with water Purge all air from the system Lower system pressure Open valves for normal sys tem operation and fill system through feed pressure Manually open air vent on the compression tank until water appears then close vent Air Pur
36. Failure to install a condensate drain in the venting system will void all warranties on this boiler Vent and Intake Air Vent Size Certified Vent Material Model No Canada Only ULC S636 PVC and CPVC Sch 40 PVC ANSI ASTM F441 Sch 40 CPVC Stainless Steel 500 AL29 4C ANSI ASTM D1785 Vertical Vent Height ft Combustion Air Intake Pipe Material Vertical Air Inlet Max Length ft Galvanized Steel PVC ABS CPVC 1 Vent lengths are based on a lateral length of 2 ft Refer to the latest edition of the NFGC for further details Subtract 10 ft per elbow Max 4 elbows Table L Category IV Vertical Vent amp Vertical Direct Vent Installation The maximum and minimum venting length for this Category IV appliance shall be determined per the NFGC U S or B149 Canada The diameter of vent flue pipe should be sized accord ing to the NFGC U S and Appendix B of B149 Canada The minimum flue pipe diameter for con ventional venting is 4 in 102mm for Models 300 and 500 and 6 in 152mm for Model 850 The connection from the appliance vent to the stack must be as direct as possible and shall be the same di ameter as the vent outlet The horizontal breaching of a vent must have an upward slope of not less than 1 4 inch per linear foot from the heater to the vent termi nal The horizontal portions of the vent shall also be supported for the design and weight of the material empl
37. ILL BE VOID IF THE HEATER RATING PLATE IS ALTERED OR REMOVED ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from Failure to properly install operate or maintain the heater in accordance with our printed instructions provided Abuse alteration accident fire flood and the like Sediment or lime build up freezing or other conditions causing inadequate water circulation High velocity flow exceeding heater design rates Failure of connected system devices such as pump or controller Use of non factory authorized accessories or other components in conjunction with the heater system Failing to eliminate air from or replenish water in the connected water system Chemical contamination of combustion air or use of chemical additives to water PARTS REPLACEMENT Under this Warranty Raypak will furnish a replacement for any failed part The failed part must first be returned to Raypak if requested with transportation charges prepaid and all applicable warranty conditions found satisfied The replacement part will be warranted for only the unexpired portion of the original warranty Raypak makes no warranty whatsoever on parts not manufactured by it but Raypak will apply any such warranty as may be provided to it by the parts manufacturer TO MAKE WARRANTY CLAIM Promptly notify the original installer supplying the model and serial numbers of the unit
38. ING Fig 15 Front Wiring Location CASCADE BUS ZONE CONTROL ONLY THERMOSTAT 0 10v L 1D 0 10v y OUTDOOR THERMOSTAT SENSOR THERMOSTAT p amp OUTDOOR OUTDOOR SEN DHW DHW SENSOR A SENSOR DHW SENSOR o 9 e OPTIONAL ALARM 5 2z uv LIGHT LIGHT 8 OFF ON WHEN WHEN t wo LOCKOUT LOCKOUT 2 2 NC H DHW o DHW NEUT Ho l2 3 DHW HOT gt 8 5 Z BOILER GRD 5 3 lm 5 eet a 2 Je BOILER NEUT 9 2n rls BOILER HOT 2 GROUND 2 NEUTRAL 12 120 VOLTS o gt Z BLACK HOT 5 amp lla 5 meric LINE VOLTAGE Sg lt IN 120 VAC CAT3 CAT 5 CONNECTION POINTS O OPTIONAL 0 10 VOLT ls E INPUT LI LI Fig 16 XFyre Single Heater Control Wiring the Thermostat 1 Connect the room thermostat to the terminals marked THERMOSTAT in the electrical junction box shown i
39. INSTALLATION amp OPERATING INSTRUCTIONS Models 300 500 amp 850 Types H amp W CERTIFIED WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Review the information in this manual carefully This unit contains materials that have been identified as carcinogenic or possibly carcinogenic to humans FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance To do so may result in an explosion or fire WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier This manual should be maintained in legible condition and kept adjacent to the heater or in a safe place for future reference a Di A Rheem Company Catalog No 1000 65 Effective 10 16 09 Replaces NEW P N 241366 Rev 1 CONTENTS WARNINGS Pay Attention to These Terms BEFORE INSTALLATION Product Receipt Model Identification Ratings and Certifications Installations at Elevatio
40. M DD YYYY Day 12 00 00 9 Clock Weekday Set day of week MM DD YY YY Day 12 00 00 10 Clock Mode Set date format MM DD YYYY Day 12 00 00 11 Clock Year Set date year MM DD YYYY Day 12 00 00 12 Clock month Set date month MM DD YYYY Day 12 00 00 13 Clock date Set date day MM DD YYYY Day 12 00 00 Press the UP arrow key to increase the tempera ture maximum setpoint is 200 F but should not exceed 180 F for H units or 160 F for W units Status Menu Installers are also able to check the current status of the XFyre unit parameters by pressing either the LEFT or RIGHT arrow keys during normal operation The status menu can have three states depending on the enabling of 0 10 VDC input and cascade master control Each state can be selected using the LEFT or RIGHT arrow key when it is enabled Service Mode This function is intended to simplify the gas valve adjustment if needed Manifold gas pressure settings 35 are listed in Table on page 16 Automatic modulation does not take place when the controller is in Test Mode only temperature limitation based on the XFyre Central Heating set point occurs The user will be allowed to increase or decrease the fan speed by pressing either the UP or DOWN arrow keys To activate the service mode press the UP arrow and ENTER MENU keys together for 1 second Once acti vated you will see in the display Service and the actual fan speed The measurement of the combustion le
41. ON This boiler requires forced water circulation when the burner is operating See minimum and maximum flow rates Severe damage will occur if the boiler is operated without proper water flow circulation CAUTION If this boiler is to be installed in a negative or positive pressure equipment room there are special installation requirements Consult factory for details NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger BEFORE INSTALLATION Raypak strongly recommends that this manual be re viewed thoroughly before installing your XFyre heater Please review the General Safety information before installing the heater Factory warranty does not apply to heaters that have been improperly installed or oper ated Refer to the warranty at the back of this manual Installation and service must be performed by a qualified installer service agency or gas supplier If after reviewing this manual you still have questions which this manual does not answer please contact your local Raypak representative or visit our website at www raypak com Thank you for purchasing a Raypak product We hope you will be satisfied with the high
42. YYY Day 12 00 00 Time of last fault 12 Fault History 2 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 13 Fault History 3 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 14 Fault History 4 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 15 Fault History 5 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 16 Fault History 6 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 17 Fault History 7 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 18 Fault History 8 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 19 Fault History 9 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault 20 Fault History 10 Fault type Fault diplay code MM DD YYYY Day 12 00 00 Time of fault Screen 3 is displayed in Cascade Mode only 36 Status Menu 2 Screen No Default Information Displayed Range Description 1 Analog DHW Temp if active Temp Fan Analog 0 10V input setpoint or fan modulation control Analog sig XX X V 0 10 0V Analog 0 10V signal Status Menu 3 Items Cascade Mode only Screen No Default Information Displayed Range Description 1 Cascade Status No Follower Cascade status Master or Follower Ready or CFH TT Sys Pump Status On On Off System pump on or off
43. ad boiler rotation time 24 hours 0 240 hours Setting 25 Cascad DHW Conf DHW Entire Cascade DHW Entire Cascade DHW Master Only 26 System Pump Freeze Enables system pump if cascade master and controlling system Protect OFF OFF to 104 F pump when outdoor temp drops below the setpoint 27 Sys Sense Fault Enable system sensor error reporting ON ON OFF Setting 28 Freeze Protect Heater freeze protection enables heater pump at return temps ON ON OFF below 44 F fires heater if temps drop below 37 F 29 DHW Demand Start Max for normal DHW operation Min for low fire start DHW Maximum Maximum Minimum 30 Extra Boiler Off if no extra boiler 100 for extra on off boiler OFF OFF 50 100 Setting 31 Sing Boil Casc Enable single boiler cascade for single boiler primary secondary OFF ON OFF operation with a system sensor 32 Maintenance Mode Installers only Enable maintenance mode alert by date or running OFF OFF RH Date hours 33 34 35 Maintenance Setting Running hours or date 36 Maintenance Setting Telephone numbers 000 000 0000 Will not display if all O s 38 Installer Menu The installer menu consists of several items that can be adjusted To access the installer menu press and the foliowi t Use th hs in Figs 33 hold the ENTER MENU key for 5 seconds Using the 16 0 owing parameters Lise tne grapns in Figs UP and DOWN and LEFT and RIGHT arrow keys and 34 to assist you in the design of the curve enter 925 the
44. ation and suitability of a vent material for application on a Category IV vent system Using improper venting materials can result in personal injury death or property damage CAUTION Raypak recommends the use of a con densate neutralizer sales order option Z 12 Use only approved PVC or CPVC vent materials in Canada ULC S636 approved plastic materials must be used or special gas vent pipes listed for use with Category IV gas burning heaters such as the AL29 4C stainless steel vents offered by Heat Fab Inc 800 772 0739 Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent manufacturer s installation instructions carefully Vent installations shall be in accordance with Part 7 Venting of Equipment of the NFGC ANSI Z223 1 NFPA 54 Section 7 Venting Systems and Air Supply for Appliances of the B149 Code or applicable provisions of the local building codes Combustion Exhaust Heater Venting Certified Vent Combustion Air Air Supply Configuration Category Materials Inlet Material Vertical Venting Vertical Venting From Inside Building Non Direct Venting Horizontal Through the Wall Venting Vertical Venting Vertical Venting Horizontal Through the Wall Venting Table K Venting Category Requirements c ul Do not use foam core or cellular core DO NOT insulate PVC CPVC vent
45. ation of the fault along with several suggestions for corrective actions Press the ESC RESET key to clear the fault and resume operation Be sure to observe the opera tion of the unit for a period of time to ensure correct operation and no reoccurrence of fault codes DANGER When servicing or replacing components that are in direct contact with the water be certain that There is no pressure in the boiler Pull the release on the relief valve Do not depend on the pressure gauge reading The boiler water is not hot The electrical power is off WARNING When servicing or replacing any components of this unit be certain that The gas is off All electrical power is disconnected WARNING Do not use this appliance if any part has been under water Improper or dangerous operation may result Contact a qualified service technician to inspect the boiler and to repair or replace any part of the boiler that has been under water prior to placing the boiler back in operation CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing CAUTION If overheating occurs or the gas supply fails to shut off do not turn off electrical power to the circulating pump This may aggravate the problem and increase the likelihood of boiler damage Instead shut off the gas supply to the boiler at the gas service valve
46. be exposed to varying weather conditions Wiring the Indirect Sensor 1 There is no indirect sensor connection required if an indirect water heater is not used in the installa tion The XFyre boiler will operate an indirect fired water heater with either a thermostat type aquas tat installed in the indirect tank or a Raypak tank sensor When a tank sensor is used the XFyre control will automatically detect its presence anda demand for heat from the indirect water heater will be generated when the tank temperature falls below the user settable setpoint by more than the user selectable offset The demand will continue until the sensor measures that the indirect water heater temperature is above the setpoint Connect the indirect tank sensor to the terminals marked DHW SENSOR shown in Fig 16 in the electrical junction box Caution should be used to ensure neither of these terminals becomes con nected to ground 20 Wiring the Optional 0 10 Volt Building Control Signal 1 A signal from a building management system may be connected to the XFyre boiler to enable remote control This signal should be a 0 10 volt positive DC signal When this input is enabled using the installer menu a building control system can be used to control either the setpoint temperature or the heat output of the XFyre boiler The control interprets the 0 10 volt signal as follows When the signal is between 0 and 1 volt the XFyre boiler will b
47. blic property 3 Within 6 ft 1 8 m of a mechanical air supply inlet to any building 4 Above a meter regulator assembly within 3 ft 915 mm horizontally of the vertical centerline of the regulator 5 Within 6 ft 1 8 m of any gas service regulator vent outlet 6 Less than 1 ft 305 mm above grade level 7 Within 3 ft 915 mm of a window or door which can be opened in any building any non mechani cal air supply inlet to any building or the combustion air inlet of any other appliance 8 Underneath a verandah porch or deck unless the verandah porch or deck is fully open on a mini mum of two sides beneath the floor and the distance between the top of the vent termination and the underside of the verandah porch or deck is greater than 1 ft 305 mm Venting Installation Tips Support piping horizontal runs at least every 5 ft 1 5m vertical runs use braces under or near elbows WARNING Examine the venting system at least once a year Check all joints and vent pipe connections for tightness corrosion or deterioration Venting Configurations For heaters connected to gas vents or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canada or applicable provisions of local building codes Vertical Venting Category IV CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions
48. condition of components are in good working order with a yes Manual Reset High Limit Setting deg F Wiring Harness Y N Operating Control Setting deg F Burner s flame Y N Refractory visual Y N Sketch plumbing on reverse side Remote flame sense Y N WATER SUPPLY Covers in place for outdoor Y N Flow Rate in GPM or Delta T If Avail Measure flow rate at full fire VENTING Pump Off Delay setting Minutes Vent Size Stack Height Low Water Cutoff Test Category sketch vent on reverse side Number of Tanks and Size Qty __ Gallons Vent Material Plumbing Size Vent Termination Type Pump Size boiler Pump HP Combustion Air Openings Low in2 Impeller trim Pump Model Ventilation air High in2 Louvers Screens EMISSIONS SETTINGS AND TEST INFORMATION Nominal Factory Recommended Settings High Low Air Intake Pressure N A In WC See manual or card tag Supply Gas Pressure In WC See manual or card tag Verify stable pressure static amp dynamic condition Manifold Gas Pressure In WC See manual or card tag The following measurements must be obtained with a Combustion Analyzer NOX PPM Less than 20 PPM If required by Certifying Agency CO PPM Less than 150 PPM CO2 96 See manual Model Number Serial Number Note draw venting with details such as extractors Site Altitude Above Sea Level Ft barometric dampers blast dampers or draft inducers Job Name Address Physical Locati
49. cow 2 1 z NC m 1 On the boiler designated as the Cascade Master 4 Hella OPTIONAL EJ al gt apply the System Sensor DHW Sensor decals gt 8 E included to the field wiring board as shown in Fig E EE 20 QU 8 5 E 18 Apply the SYSTEM PUMP and EXT HEATER BOER HOT A a TTE labels to the wiring electrical connections terminal 2 7418 s NEUTRAL sz strip as shown in Fig 11b on page 17 A BLACK HOT S f 2 Connect the system pump hot wire to terminal 11 2 marked SYSTEM PUMP see Fig 11b GREEN GROUND 5 WHITE NEUTRAL BLACK HOT 3 Connect the system pump neutral to terminal 6 LINE VOLTAGE 5 marked BOILER PUMP NEUT and the pump IN 120 VAG O ground wire to terminal 3 marked GROUND at the rear terminal strip Fig 19 XFyre Cascade Follower 4 Connect a jumper wire from terminal 1 marked 120 V BLACK HOT terminal 11 marked SYS TEM PUMP POWER at the rear terminal strip 22 Cascade Follower Pump and Sensor Wiring 1 Connect the boiler pump to the terminals marked BOILER PUMP NEUT 6 BOILER PUMP HOT 5 and GROUND 4 at the rear term
50. cts optional 0 10 VDC control wiring and cas cade connections are wired into the front mounted field wiring board as shown in Fig 15 19 Field Connected Controllers It is strongly recommended that all individually pow ered control modules and the heater should be supplied from the same power source NOTE Field supplied isolation relays should be installed when field connected controllers are mounted more than 50 equivalent feet 18 AWG from heater Check the Power Source NOTE Minimum 18 AWG 105 C stranded wire must be used for all low voltage less than 30 volts external connections to the unit Solid conductors should not be used because they can cause excessive tension on contact points Install conduit as appropriate All high voltage wires must be the same size 105 C stranded wire as the ones on the unit or larger CBA Fig 12 Wiring Connections WARNING Using a multi meter check the following voltages at the circuit breaker panel prior to connecting any equipment Make sure proper polarity is followed and house ground is proven See Fig 13 Check the power source AC 108 VAC Minimum 132 VAC MAX AB 108 VAC Minimum 132 VAC MAX BC lt 1 VAC Maximum 18 Fig 13 Multi meter Making the Electrical Connections Refer to Fig 11 19 1 Verify that circuit breaker is properly sized by referring to heater rating plate
51. d directly to the boiler Indoor Units This heater must be supplied with sufficient quantities of non contaminated air to support proper combustion and equipment ventilation Combustion air can be sup plied via conventional means where combustion air is drawn from the area immediately surrounding the heater or via direct vent where combustion air is drawn directly from outside All installations must com ply with the requirements of the NFGC U S and B149 Canada and all local codes CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the boiler and void the warranty See the Appendix NOTE It is recommended that the intake vent be insulated in cold climates to minimize sweating INSIDE CORNER DE TAIL VLLLLLLLL LL A 2 lt e Fig 5 Minimum Clearances from Vent Air Inlet Terminations Indoor and Outdoor Installations Clearance above grade veranda porch deck or balcony Canadian Installations U S Installations 1 ft 30 cm 1 30 cm Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal dis tance of 2 ft 61cm from the centerline of the terminal 4 ft 1 2m below or to side of opening 1 foot 30 cm above opening 3 ft 91 cm Clearance to unventilated soffit Clearance to outside
52. e NFGC under Engineered Vent Sys tems Table M provides volumes of flue products at full fire for the calculation of appropriate vent and extractor sizing for common venting WARNING Vent connectors serving any other appliances shall not be connected into any portion of mechanical draft systems operating under a positive pressure If an XFyre boiler is installed to replace an existing boiler the vent system MUST be verified to be of the correct size and of Category IV AL29 4C vent material or approved PVC CPVC construction in Canada ULC S636 approved plastic materials must be used If it is NOT it MUST be replaced NOTE For extractor sizing typical CO levels are 8 596 for natural gas and 9 596 for propane gas and flue temperatures of approximately 150 F At the time of removal of an existing boiler the follow ing steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remain ing connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and make sure there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c As much as possible close all building doors and windows and all doors between the space in which the appliances rema
53. e in stand by mode not firing When the signal rises above 1 volt the XFyre boiler will ignite As the signal continues to rise towards its maximum of 10 volts the XFyre boiler will increase either in setpoint temperature or firing rate depending on the setting of screen 17 in the installer menu See the Installer Menu section for details on the setting of screens 16 and 17 for this option Connect a building management system or other auxiliary control signal to the terminals marked 0 10 V and 0 10 V in the electrical junction box shown in Fig 16 Caution should be used to ensure that the 0 10 V connection does not become connected to ground Wiring the Cascade System Communication Bus 1 Use standard CAT3 or CAT5 computer network patch cables to connect the communication bus between each of the boilers These cables are readily available at any office supply computer electronic department or discount home supply store in varying lengths It is recommended that the shortest length cable possible be used to reach between the boilers and create a neat installation Do not run unprotected cables across the floor or where they will become wet or damaged Avoid running communication cables parallel with or close to or against high voltage 120 volt or greater wiring Raypak rec ommends that the total maximum length of communication bus cables not exceed 200 feet ZEE
54. e mounted with its spindle vertical see Fig 1 2 and 3 on page 6 Relief valve discharge piping shall provide no less than the cross sectional area of the relief valve outlet and must be routed to a safe point of discharge Installation must comply with all national state and local codes WARNING The pressure relief valve must be installed at the outlet of the boiler No valve is permitted to be installed between the boiler and the relief valve Temperature amp Pressure Gauge The temperature and pressure gauge is shipped loose for field installation and must be installed within 12 inches of the boiler outlet if possible in an easily readable location Installation must comply with ASME Section IV as well as all applicable national state and local codes Hydrostatic Test Unlike many types of heaters this heater does not re quire hydrostatic testing prior to being placed in operation The heat exchanger has already been fac tory tested and is rated for 160 psi operating pressure However Raypak does recommend hydrostatic test ing of the piping connections to the heater and the rest of the system prior to operation This is particularly true for hydronic systems using expensive glycol based anti freeze Raypak recommends conducting the hydrostatic test before connecting gas piping or electrical supply Leaks must be repaired at once to prevent damage to the heater NEVER use petroleum based stop leak compounds
55. e sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspec tor observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 53 b EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for res idential purposes c MANUFACTURER REQUIREMENTS GAS EQUIP MENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instruc tions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting sys tem design or the venting system components and 2 A complete parts list for the venting system design or vent ing system d MANUF
56. ect Spark Igniter 48 MAINTENANCE Suggested Minimum Maintenance Schedule Regular service by a qualified service agency and maintenance must be performed to ensure maximum operating efficiency Maintenance as outlined below may be performed by the owner Daily 1 Check that the area where the boiler is installed is free from combustible materials gasoline and other flammable vapors and liquids 2 Check for and remove any obstruction to the flow of combustion or ventilation air to boiler Monthly 1 Check for piping leaks around pumps mixing valves relief valves and other fittings If found repair at once DO NOT use petroleum based stop leak compounds 2 Visually inspect burner flame 3 Visually inspect venting system for proper func tion deterioration or leakage 4 Visually inspect for proper operation of the con densate drains in the venting and the internal condensate trap Clean trap as necessary If leaks are observed repair at once 5 Check air vents for leakage Yearly Beginning Of Each Heating Season Schedule annual service call by qualified service agency 1 Visually check top of vent for soot Call service person to clean Some sediment at bottom of vent is normal 2 Visually inspect venting system for proper func tion deterioration or leakage Ensure that condensate drain is inspected and ensure that condensate is being directed to appropriate con densate management s
57. ected by the vent manufacturer 2 The vent must be installed with a slight upward slope of not more than 1 4 inch per foot of hori zontal run to the vent terminal Termination The vent cap MUST be mounted on the exterior of the building The vent cap cannot be installed in a well or below grade The vent cap must be installed at least 1 ft above ground level and above normal snow levels The vent cap MUST NOT be installed with any com bustion air inlet directly above a vent cap This vertical spacing would allow the flue products from the vent cap to be pulled into the combustion air intake installed above This type of installation can cause non warrantable problems with components and poor operation of the boiler due to the recirculation of flue products Multi ple vent caps installed in the same horizontal plane must have a 4 ft clearance from the side of one vent cap to the side of the adjacent vent cap s Combustion air supplied from outdoors must be free of particulate and chemical contaminants To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants 5 Vent terminal must be at least 3 ft above any forced air inlet located within 10 ft 6 Adjacent brick or masonry surfaces must be pro tected with a rust resistant sheet metal plate F
58. eneral purpose hot water the rec ommended initial setting for the temperature control is 125 F Safety and energy conservation are factors to be con sidered when setting the water temperature on the thermostat The most energy efficient operation will result when the temperature setting is the lowest that satisfies the needs of the application Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded e Feel water before bathing or showering Temperature limiting valves are available NOTE When this heater is supplying general purpose hot water for use by individuals a thermostatically controlled mixing valve for reducing point of use water temperature is recommended to reduce the risk of scald injury Contact a licensed plumber or the local plumbing authority for further information Maximum water temperatures occur just after the heater s burner has shut off To determine the water temperature being delivered turn on a hot water faucet and place a thermometer in the hot water stream and read the thermometer CAUTION Hotter water increases the risk of scalding There is a hot water scald potential if the thermostat is set too high Water temperature over 125 F can cause instant severe burns or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before s
59. energize the equipment before servicing Ignition Control Functions When there is a call for heat the combustion air blow er starts to purge air from the combustion chamber After the pre purge the igniter is energized The stan dard ignition module will lock out after failing to light four times or after losing flame three times during a single heat demand To reset it press and release the ESC RESET button located on the user interface The control will automatically reset after 1 hour When in lock out the control will run the blower for a 1 minute purge cycle Turning off the power to the heater WILL NOT reset the ignition module The optional single try ignition module will attempt to light only one time before locking out To reset it press the ESC RESET button on the user interface NOTE Each ignition module is specific to a single model size Care should be taken not to use a mod ule intended for a different model size 32 High Limit Manual Reset This boiler is equipped with a fixed setting manual re set high limit temperature device as standard or it may have an optional adjustable setting manual reset high temperature device The fixed setting manual reset high limit is located on the outlet pipe of the heat exchanger on the left side of the boiler accessible through the front door for reset as necessary Fig 26 High Limit Manual Reset High Limit Auto Reset Optional This
60. er with appropriate valves to prevent the chilled medium from entering the heater The piping system of a hot water heater connected to heating coils located in air handling units where they may be exposed to circulating refrigerated air must be equipped with flow control valves or other automatic means to prevent gravity circulation of the heater water during the cooling cycle It is highly recommend ed that the piping be insulated Air Separation Expansion Tank EXPANSION TANK AIR SEPARATOR WITH BLEED VALVE Fig 6 Air Separation Expansion Tank All heaters should be equipped with a properly sized expansion tank and air separator fitting as shown in Fig 6 above Three Way Valves Three way valves intended to regulate system water temperatures by reducing flow in the boiler should not be used Raypak heaters are high recovery low mass heaters which are not subject to thermal shock Maximum 4 times the pipe diameter or 12 whichever is less Fig 7 Single Heater Low Temperature Heat Pump Application with Primary Secondary Piping Model 20 F AT 30 F AT Maximum 4 times the pipe diameter or 12 whichever is less Fig 8 Dual Heaters Reverse Return with Primary Secondary Piping Domestic Hot Water When designing the water piping system for domestic hot water applications water hardness should be con sidered Table H indicates the suggested
61. ervice is needed Reasonable proof of the effective date of the warranty date of installation must be presented otherwise the effective date will be based on the date of manufacture plus thirty 30 days Original Owner Model Number Serial Number Mailing Address Date of Installation City State Zip Code Installation Site Daytime Telephone Number Contractor Installer RAYPAK INC 2151 Eastman Avenue Oxnard CA 93030 9786 805 278 5300 Fax 800 872 9725 www raypak com 54 START UP CHECKLIST FOR THE XFYRE This start up checklist is to be completely filled out by the service technician starting up the Raypak Boiler or Heater for the first time All information may be used for warranty purposes and to ensure that the installation is correct Additionally this form will be used to record all equipment operation functions and required settings GAS SUPPLY DATA CLEARANCES Regulator Model amp Size CFH Front Clearance In Gas Line Size in room In NPT Right Side Clearance In Length of Gas Line Eq Ft Left Side Clearance In Low Gas Pressure Setting In WC Rear Clearance In High Gas Pressure Setting In WC Overhead Clearance In Gas Shut Off Valve Type Ball Lube cock ELECTRICAL Sediment Trap Y N Voltage Supply VAC No Load Load Port Std Full Voltage 24 VAC VAC Voltage Com to Ground VAC VISUAL INSPECTION OF COMPONENTS Auto High Limit Setting deg F Verify inspection was done and
62. ess the ENTER MENU key to select it The screen will begin to flash Press the DOWN arrow key to decrease the values and the UP arrow key to increase them To store the changes press the ENTER MENU key The display returns to normal mode after one minute Pressing the ESC RESET key before storing changes will restore the original value Refer to Fig 32 for dis play and key locations Adjusting the XFyre Setpoint To adjust the temperature on the XFyre Press the ENTER MENU key for 5 seconds to bring up the code menu Enter 600 to access the user menu Press the DOWN arrow key to decrease the tem perature minimum setpoint is 50 F UP arrow DOWN key arrow key SCROLL sono gt Ay Y MENU ESC RESET LEFT arrow RIGHT ENTER MENU key key arrow key key Fig 32 Display Interface User Menu Items Screen No Default Information Displayed Range Description 1 Heat Loop Cascade or heat loop setpoint 159 F 50 190 F 2 Heat Loop Diff Cascade or heat loop differential 30 F 2 45 F 3 DHW Set DHW Setpoint 140 F 95 185 F 4 DHW Diff DHW Differential 5 F 1 18 F 5 Temperature Unit Temperature unit of measure oF 6 Clock Mode Clock mode 12 or 24 hour MM DD YYYY Day 12 00 00 12 24 h 1 Clock Hour Set clock hour MM DD YY YY Day 12 00 00 8 Clock Minute Set clock minute M
63. et ting temperature at water heater Feel water before bathing or show ering Temperature limiting valves are available see manual Time Temperature Relationships in Scalds The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications Water Time to Produce Serious Temp Burn 120 More than 5 minutes 125 F 1 1 2 to 2 minutes 130 F About 30 seconds Table courtesy of The Shriners Burn Institute Table C Time to Produce Serious Burn INSTALLATION Installation Codes Installations must follow these codes Local state provincial and national codes laws regulations and ordinances National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition NFGC National Electrical Code ANSI NFPA 70 edition NEC e Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 CSD 1 when required e For Canada only CAN CSA B149 Natural Gas and Propane Installation Code and CSA C22 1 C E C Part 1 C22 1 latest Equipment Base The heater must be mounted on a level structurally sound surface The heater is approved for installation on a combustible surface but must NEVER be installed on carpeting Gas fueled equipment installed in enclosed parking garages must be located at least 18 in above the floor CAUTION The boiler must be leve
64. f available connect PC and using service software check the 24v supply display in the lower left cor ner of the screen The number displayed here must be greater than 128 and should be greater than 250 Use this as a troubleshooting guide as you follow the steps below 3 Remove 10 pin Molex connector from customer connection board If LOU code clears then the prob lem is with external sensor wiring Examine external sensor wiring for shorts to ground repairing as necessary If LOU code is still present and the boiler is so equipped disconnect high gas pressure Switch then low gas pressure switch then UL 353 low water cutoff in this order one at a time to see if LOU code clears Replace faulty part Check low voltage wire harness in boiler for shorts to ground 4 If LOU only occurs when burner tries to light check gas valve for excessive current draw 5 If LOU is present with the low voltage harness disconnected from the control board replace the con trol board 24 VOLT LOW LOU LOW WATER FLOW if unit is operating or TEMPER BLOCKING if Flow Switch is OFF 1 Check to see if boiler circulator is functioning Repair as necessary 2 Make sure water is flowing in the system Check for valves that should be open plugged filter screens etc 3 Check flow switch and wiring Repair as necessary 1 Check circulation pump operation 2 Ensure that there is adequate flow through the boiler by accessing the status menu and assuring that
65. g is not transfered to the unit Horizontal runs of vent and intake piping must be supported to prevent sagging 27 EXTRACTOR S PRESSURE SET POINT SLOPE TOWARD APPLIANCE 1 IN 4 MINIMUM COMMON VEN T PIPE CAT II b vmi NN SPEED EXTRACTOR ccc ALT LOCATION VARIABLE SPEED EXTRACTOR 2 7 lt Kd 2 Note Heaters rotated to show venting connections Fig 21 Typical Common Venting Horizontal Through the Wall Direct Venting Category IV N HEATER UNIT NN 12 VENT TERMINAL 12 MIN ABOVE SNOWLINE 2 7 42 Refer to Table F and local codes Fig 22 Horizontal Through the Wall Venting 28 HEATER UNIT ADJUSTABLE VENT DAMPER BAFFLE VENT PIPE SAME DIAMETER AS BOILER VENT L VENT DRAIN USE TEFLON TUBING RUN TO FLOOR DRAIN OR CONDENSATE PUMP INSULATED EXHAUST VENTING FLUE EXHAUST VENT CAP 12 MIN 15 INTAKE ELBOW 12 MIN ABOVE SHOWLINE 7 v CONDENSATE TRAP Refer to Table F and local codes Fig 23 Horizontal Through the Wall Direct Venting NOTE While drain connection is required in the vent of all XFyre installations the drain can be ac complished in several different ways The figures in this manual show the drain in a
66. ge Domestic Hot Water Heaters CAUTION An air vent should be installed at the highest point in the system for proper operation If water piping is located higher than the boiler it should be relocated to the highest point in the installed system Purge all air from system before lighting heater This can be normally accomplished by opening a down stream valve Venting System Inspection 1 Check all vent pipe connections and flue pipe ma terial WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 2 Make sure vent terminations are installed per code and are clear of all debris or blockage For Your Safety This appliance has a direct spark igniter It is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 41 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell near the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neigh bors telephone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas con trol knob Never use
67. heater is equipped with a fixed auto reset high limit temperature device The optional auto reset high limit is located on the heat exchanger header near the outlet Fig 27 High Limit Auto Reset Flow Switch This standard dual purpose control mounted and wired in series with the main gas valve shuts off the boiler in case of pump failure or low water flow Fig 27 Flow Switch Low Water Cut Off Optional The optional low water cut off automatically shuts down the burner whenever water level drops below the level of the sensing probe A 5 second time delay pre vents premature lockout due to temporary conditions such as power fluctuations or air pockets f S uj Fig 28 Low Water Cut Off High amp Low Gas Pressure Switches Optional The optional low gas pressure switch connection mounts upstream of the gas valve on the inlet flange to the gas valve and is accessible through the remov able access panels on the rear of the boiler to reset the gas pressure switch as necessary t is used to ensure that sufficient gas pressure is present for prop er valve regulator performance The low gas pressure switch automatically shuts down the boiler if the gas supply drops below the factory setting of 3 0 in WC for natural gas or propane gas 33 The optional high gas pressure switch connection mounts down stream of the gas valve Special ports are located on the backside of the gas valve and acce
68. in the gas supply piping adja cent to the heater for servicing The gas supply pressure to the heater must not exceed 10 5 in WC for natural gas or 13 0 in WC for propane gas A pounds to inches regulator must be installed to reduce the gas supply pressure if it is higher than noted above This regulator should be placed a minimum distance of 10 times the pipe diameter upstream of the heater gas controls Refer to Table J for maximum pipe lengths Gas Supply Connection CAUTION The heater must be disconnected from the gas supply during any pressure testing of the gas supply system at test pressures in excess of 1 2 psi 3 45 kPa The heater must be isolated from the gas supply pip ing system by closing the upstream manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psi 3 45 kPa Relieve test pressure in the gas supply line prior to re connecting the heater and its manual shut off valve to the gas supply line FAILURE TO FOLLOW THIS PROCEDURE MAY DAMAGE THE GAS VALVE Over pressurized gas valves are not covered by warranty The heater and its gas con nections shall be leak tested before placing the appliance in operation Use soapy water for leak test DO NOT use an open flame UST BE SUPPLIED BY INSTALLER M MANUAL BALL VALVE UNION WRENCHING NIPPLE n ko
69. inal strip 2 If you are using an indirect fired water tank con nected directly to the follower boiler connect the pump for it to the terminals marked DHW PUMP NEUT 8 DHW PUMP HOT 7 and GROUND 3 at the rear terminal strip If you desire an alarm bell or light can be connected to the alarm contacts of the follower boiler Optionally the normally closed alarm contact may be used to turn a device off if the boiler goes into lockout mode The alarm contacts are rated 5 amps at 120 VAC To connect an alarm device connect the power for the device to the ALARM COM terminal Connect the alarm device hot wire to the ALARM NO terminal Connect the neutral or return of the alarm device to the neutral or return of the power for the alarm device To connect a device that should be powered off during a boiler lockout condition follow the same instructions as above except use the ALARM NC terminal rather than the ALARM NO terminal Note that in a cascade system the alarm output of the boiler addressed as 1 will also be active if the master boiler has a lockout condition The alarm output of boil ers addressed as 2 7 will only sound if a lockout condition occurs on that specific boiler CAUTION Proper installation of flue venting is critical for the safe and efficient operation of the boiler Venting General Appliance Categories Heaters are divided into four categories based on the pressure produced in the exhaust and
70. ing parts of all safety shut off and control valves and increase or decrease settings depending on the type of control until the safety circuit opens 50 Reset to original setting after each device is test ed Perform leakage test on gas valves Test air switch in accordance with manufacturer s instructions Turn panel switch to the posi tion until blower is proven then turn the switch to Off Inspect and clean burner using shop air Clean the combustion chamber coil using the pro cedure on the following page As Required 1 Recondition or replace low water cut off device if equipped Check drip leg and gas strainers Check flame failure detection system See Post Start Up Check Verify high and low fire flame signal compare to start up data Check igniter Clean and verify spark gap see Fig 36 Check fan speed and manifold pressure See Blower Check and Manifold Check Test safety safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV WARNING The combustion chamber insulation in this product contains ceramic fiber material Ceramic fibers can be converted to cristobalite in very high temperature applications The International Agency for Research on Cancer IARC has concluded that Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group1 Avoid breathing du
71. ining connected to the com mon venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will oper ate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e After it has been determined that each appliance remaining connected to the common venting sys tem properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use Any improper operation of the common venting system should be corrected so that the installation conforms with the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 and or CAN CSA B149 Volume of Flue Products CFM Vent Size inches Model No 4 m e Table M Volume of Flue Products Data NOTE Data for 100 firing rate NOTE Vent and intake piping must be supported so that the weight of the ventin
72. ir which raise the acidity of the condensate Higher acidity levels attack many materials including stainless steel which is commonly used in high effi ciency systems The boiler can be supplied with corrosion resistant non metallic intake air vent materi al You may however choose to use outside combustion air for one or more of these reasons 1 Installation is in an area containing contaminants listed below which will induce acidic condensation 2 You want to reduce infiltration into your building through openings around windows and doors 3 You are using AL29 4C stainless steel vent pipe which is more corrosion resistant than standard metallic vent pipe In extremely contaminated ar eas this may also experience deterioration Products causing contaminated combustion air Spray cans containing chloro fluorocarbons e permanent wave solutions e chlorinated waxes cleaners e chlorine based swimming pool chemicals calcium chloride used for thawing e sodium chloride used for water softening refrigerant leaks e paint or varnish removers hydrochloric acid muriatic acid e cements and glues e antistatic fabric softeners used in clothes dryers e chloride type bleaches detergents and cleaning solvents found in household laundry rooms adhesives used to fasten building products similar products Areas where contaminated combustion air commonly exists dry cleaning laundry areas metal fabrication
73. l combustion air filter This filter will reduce the amount of particulates that pass through the combustion system and heat exchanger but will not protect against chemical inside air contamination See Appendix The filter must be checked periodically to verify that adequate combus tion air is being supplied to the heater See the Maintenance section of this manual for information on checking the filter and establishing service intervals Direct Vent If outside air is drawn through the intake pipe directly to the unit for combustion 1 Install the combustion air ducting kit 2 Install combustion air direct vent in accordance with Fig 23 horizontal or Fig 24 vertical of this manual Provide adequate ventilation of the space occu pied by the heater s by an opening s for ventilation air at the highest practical point com municating with the outdoors The total cross sectional area shall be at least 1 in of free area per 20 000 BTUH 111 mm per kW of total input rating of all equipment in the room when the opening is communicating directly with the out doors or through vertical duct s The total cross sectional area shall be at least 1 in of free area per 10 000 BTUH 222 mm per kW of total input rating of all equipment in the room when the opening is communicating with the outdoors through horizontal duct s In cold climates and to mitigate potential freeze up Raypak highly recommends the installation of a
74. l to allow condensate to drain properly from the heat exchanger CAUTION This boiler should be located in an area where water leakage will not result in damage to the area adjacent to the appliances or to the structure When such locations cannot be avoided it is recommended that a suitable catch pan adequately drained be installed under the appliance The pan must not restrict air flow In addition the heater shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation or service circulator replacement control replacement etc If the heater needs to be secured to the ground use the holes in the anchoring legs on the heater Clearances Indoor Installations Recommended Service Clearances Min Clearances from Combustible Surfaces Heater Side Floor Rear Left Side Front Vent DO NOT install on carpeting Table D Clearances Indoor Installations When installed according to the listed minimum clear ances from combustible construction these heaters can be serviced without removing permanent structur al construction around the heater However for ease of servicing we recommend a clearance of at least 24 in in front at least 24 in on the rear and 24 in above the top of the heater This will allow the heater to be serviced in its installed location without movement or removal of the heater
75. ly thermistor 3 Troubleshoot thermistor by following steps in SUPPLY THERMISTR F02 1 Watch the igniter through the observation window provided 2 If there is no spark check the spark electrode for the proper 7 gap Use 2 quarters together as a gauge to hold igniter against to check gap distance 3 Remove any corrosion from the spark electrode and flame rectifier probe 4 If there is a spark but no flame check the gas supply to the boiler 5 If there is a flame check the flame sensor 6 Check any flue blockage or condensate blocks 1 Monitor the gas pressure to the unit while in operation 2 Ensure that the flame is stable when lit 3 Check to see if the green light on the display module is out while the boiler is running 4 If the green light doesn t come or goes off during operation check the flame signal on the status menu 5 If the signal reads less than 1 microampere clean the flame rectifier probe 6 If the flame rectifier probe continues to read low replace it 7 Check the stability of the flame rectification signal If the signal is unstable you may need to replace the burner gasket 1 Look into window If there is flame turn the gas off to the unit at the service valve and replace gas valve 2 If the flame signal is present and there is no flame replace the flame rectification probe 3 If the flame signal is not present after turning off the gas supply check the gas valve electrical connection
76. me Should see light blue flame at full input rate Weekly For low pressure boilers test low water cut off device With boiler in pre purge depress the low water cut off test button Appliance should shut off and ignition fault light should come on Depress reset button on front of heater control panel to reset Monthly 1 Check flue vent stack or outlet dampers 2 Test intake air pressure See Table Q Replace the filter when the intake air pressure increases by 0 5 in WC from the reading recorded on the start up checklist 3 Test high and low gas pressure interlocks if equipped See Safety Inspection Semi Annually 1 Recalibrate all indicating and recording gauges 2 Check flame failure detection system components 3 Check firing rate control by checking the manifold pressure See Manifold Check 4 Check piping and wiring of all interlocks and shut off valves Annually 1 Test flame failure detection system and pilot turn down 2 Test high limit and operating temperature See Post Start Up Check 3 Check flame sensor 4 Conduct a combustion test at high and low fire Carbon dioxide should be 8 5 to 9 0 at full fire for natural gas and between 9 0 to 9 5 for propane gas Carbon monoxide should be lt 150 ppm 5 Check valve coil for 60 cycle hum or buzz Check for leaks at all valve fittings using a soapy water solution while unit is operating Test other oper at
77. motorized sealed damper on the air intake to prevent the circulation of cold air through the heater during the non operating hours TruSeal Combustion Air In addition to the 4 previous steps combustion air may be ducted directly to the heater by using PVC CPVC or sealed single wall galvanized ducting The duct will attach directly to the air collar located on the rear of the heater when the combustion air ducting kit is installed using three or four sheet metal screws not supplied equally positioned around the circumference of the duct The screws and duct connection point must be sealed with RTV not supplied TruSeal is generally used when damaging contaminants are present in the 11 mechanical room All ducting must be self supported CAUTION Use TruSeal combustion air if damaging airborne contaminants are or may be present in the boiler area See the Appendix of this manual regarding air contamination Conventional Combustion Air Supply U S Installations Air from Inside the Building The confined space shall be provided with TWO per manent openings communicating directly with an additional room s of sufficient volume so that the com bined volume of all spaces meets the criteria for a room large in comparison NFGC The total input of all gas utilization equipment installed in the combined space shall be considered in making this determina tion Each opening shall have a minimum free area of 1 in pe
78. n Component Locations General Information Time Temperature Relationships in Scalds GENERAL SAFETY INSTALLATION Installation Codes Equipment Base Clearances Combustion and Ventilation Air Conventional Combustion Air Supply Water Piping Hydronic Heating Gas Supply Electrical Power Connections Field Wiring Connection Venting Venting Installation Tips Venting Configurations Outdoor Installation Controls Operating Instructions WIRING DIAGRAM START UP Pre Start up Pre Start up Check Initial Start up Preparation Start Up OPERATION Lighting Instructions To Turn Off Gas to Appliance XFyre Error Codes Heater Errors Heater Faults TROUBLESHOOTING XFyre Fault Text Sensor Resistance Values MAINTENANCE Suggested Minimum Maintenance Schedule Preventive Maintenance Schedule APPENDIX Inside Air Contamination Important Instructions for the Commonwealth of Massachusetts WARRANTY START UP CHECKLIST WARNINGS Pay Attention to These Terms Indicates the presence of immediate hazards which will cause severe personal injury death or substantial property damage if ignored Indicates the presence of hazards or unsafe practices which could cause severe personal injury death or substantial property damage if ignored Indicates special instructions on installation operation or maintenance which Indicates the presence of hazards or unsafe practices which could cause minor personal i
79. n Fig 16 Alternately any dry contact closure across these terminals will enable the XFyre unit to run Caution should be used to ensure neither of the terminals becomes connect ed to ground Mount the thermostat on an inside wall as central as possible to the area being heated but away from drafts or heat producing devices such as tel evision sets that could effect the ability of the thermostat to measure the room temperature accurately If the thermostat is equipped with an anticipator and it is connected directly to the XFyre boiler the anticipator should be set at 1 amps If the thermo stat is connected to other devices the anticipator should be set to match the power requirements of the device it is connected to See the instruction manual for the connected devices for further infor mation 19 Wiring the Outdoor Sensor 1 There is no connection required if an outdoor sen sor is not used in this installation If using an Outdoor Sensor connect the wires for sensor to the terminals marked OUTDOOR SEN shown in Fig 16 in the electrical junction box Caution should be used to ensure neither of these terminals becomes connected to ground Use a minimum 22 AWG wire for runs of 100 feet or less and minimum 18 AWG wire for runs of up to 150 feet Mount the outdoor sensor on an exterior surface of the building preferably on the north side in an area that will not be affected by direct sunlight and that will
80. n press ENTER MENU Scroll through the list of adjustable items by pressing the LEFT or RIGHT arrow keys Once the desired item is dis played press the ENTER MENU key to select it The d 1g mis t P Function 9 screen will begin to flash Press the DOWN arrow key OSA eae to decrease the values and the UP arrow key to increase them To store the changes press the ENTER MENU key The display returns to normal mode after one minute Pressing the ESC RESET key before storing changes will restore the original value To set your own custom heat curve you will have to set 1 Minimum outside design temperature Function 8 3 Maximum outside design temperature Function 10 4 Design Supply Water Temperature at the maxi mum outside temperature Function 11 The central heating demand is detected when the room thermostat closes When an outside sensor is also connected the supply temperature will depend on the factory default central heating curve which is suffi NOTE It is important to note that the user can cient for most applications adjust the heat curve down by adjusting the central heating temperature to a lower setting OUTDOOR RESET CURVE OUTDOOR RESET CURVE Factory Default Plot your Curve 212 212 203 203 201 194 194 185 185 176 FUNCTION 9 176 167 167 158 158 DEFAULT RESET CURVE
81. n the same gas main check all pressures on the XFyre with all other equipment running 4 Check thermostats for ON OFF operation 5 Check high limits for ON OFF operation 6 While in operation check flow switch operation 7 Check the low gas pressure switch if provided For proper adjustment use the attached manometers if available to set pressure The scales on the switch are approximate only Low gas pressure switch if provided must be set at 3 0 in WC for natural gas and propane gas 8 Make sure that the high gas pressure switch op tional is set to 3 0 in WC for both natural gas and propane gas Follow Up Safety checks must be recorded as performed Turn boiler on After main burner ignition 1 Check manometer for proper readings Specifically note the change in air intake pressure Replace the filter if necessary Refer to Table Q 2 Cycle unit several times and re check readings 3 Remove all manometers and replace caps and Screws 4 Check for gas leaks one more time Post Start Up Check Check off steps as completed 1 10 11 12 Verify that the boiler and heat distribution units or storage tank are filled with water Confirm that the automatic air vent if used was opened two full turns during the venting proce dure Verify that air has been purged from the system Verify that air has been purged from the gas pip ing and that the piping has been checked for leaks
82. ng the ASME or CSA ratings of the vessel also violates national state and local approval codes Installations at Elevation Rated inputs are suitable for up to 2000 ft elevation without de rating Consult your local representative or the factory for installations at altitudes over 2000 ft above sea level No hardware changes are required to the heaters for installations up to 10 000 ft adjust ments may be required Component Locations COMPONENT LOCATIONS SIDES PANELS REMOVED FOR CLARITY FLOW SWITCH FRONT OF HEATER Model 300 shown Component locations may vary slightly in larger models Fig 1 Component Locations Sides NES COMPONENT LOCATIONS TOP TOP PANEL FLUE REMOVED FOR CLARITY OUTLET WATER OUTLET ELECTRICAL CONNECTIONS T S LU i COMPONENT LOCATIONS REAR Fig 3 Component Locations Rear Fig 2 Component Locations Top General Information Gas conn Vent Size inches seo oo Css se wo z Table A Basic Data 6 Table Heater Water Volume GENERAL SAFETY To meet commercial hot water use needs the high limit safety control on this water heater will shut off the main gas valve before the outlet temperature reaches 210 F However water temperatures over 125 F can cause instant severe burns or death from scalds When supplying g
83. njury or product or property damage if ignored are important but not related to personal injury hazards DANGER Make sure the gas on which the boiler will operate is the same type as that specified on the boiler rating plate WARNING Should overheating occur or the gas supply valve fail to shut do not turn off or disconnect the electrical supply to the boiler Instead shut off the gas supply at a location external to the boiler WARNING Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water WARNING To minimize the possibility of improper operation serious personal injury fire or damage to the boiler Always keep the area around the boiler free of combustible materials gasoline and other flammable liquids and vapors Boiler should never be covered or have any blockage to the flow of fresh air to the boiler WARNING Risk of electrical shock More than one disconnect switch may be required to de energize the equipment before servicing WARNING CALIFORNIA PROPOSITION 65 This product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CAUTION If this boiler is to be installed above radiation level it must be provided with a low water cut off device at the time of boiler installation CAUTI
84. om of the vent terminal and the air intake shall be located at least 12 in above grade includ ing normal snow line Single wall Category IV metal vent pipe shall not be used outdoors in cold climates for venting gas fired equipment without insulation Through the wall vents for Category IV appli ances shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimen tal to the operation of regulators relief valves or other equipment Locate and guard vent termination to prevent acci dental contact by people or pets DO NOT terminate vent in window well stairwell alcove courtyard or other recessed area 10 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet metal backing plate against brick or mason ry surfaces 12 DO NOT extend exposed vent pipe outside of building beyond the minimum distance required for the vent termination Condensate could freeze and block vent pipe NOTE When using PVC vent termination insert the two round stainless mesh screens provided with the unit into the tee 24 U S Installations Refer to the latest edition of the National Fuel Gas Code Vent termination requirements are as follows 1 Vent must terminate at least 4 ft below 4 ft hori
85. on CAUTION This boiler requires forced water circulation when the burner is operating See Table G and Table H for minimum and maximum flow rates 2 For heaters using a barometric damper in the vent system there shall be a permanent air supply opening s having a cross section area of not less m than 1 in 2 7 000 BTUH 320 mm kW up NOTE Minimum pipe size for in out connections is to and including 1 million BTUH plus 1 in 2 per 1 1 2 NPT for model 300 and 2 NPT for models 500 14 000 BTUH 160 mm per kW in excess of 1 and 850 Verify proper flow rates and AT as instruct million BTUH This opening s shall be either d in this manual located at or ducted to a point not more than 18 in 450 mm nor less than 6 in 152 mm above the floor level The duct can also goose neck through the roof The duct is preferred to be straight down 12 Relief Valve Installation and Piping WARNING Pressure relief valve discharge piping must be piped near the floor and close to a drain to eliminate the potential of severe burns Do not pipe to any area where freezing could occur Refer to local codes The heater is supplied with a Section IV HV stamped relief valve sized for the full input of the unit The relief valve assembly is shipped loose and must be mount ed directly to the heater outlet No valve shall be installed between the heater and the relief valve The relief valve shall b
86. on of Boiler Indoors Outdoors Ground Level Roof Below Grade Mechanical Contractor Installer Date and Time of Start up Print Name and Signature of Start up Technician Information must be faxed to 805 278 5471 in order to ensure warranty consideration Attn Service Manager 55 Registered Quality Management System www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 56
87. ot try to light the burner by hand Turn on main manual gas valve field installed near gas inlet connection on back of boiler Wait 5 minutes to clear out any gas Then smell for gas especially near the floor If you then smell gas STOP Follow the steps in the safety informa tion on the front cover of this manual If you do not smell gas go to next step Turn on all electrical power to the appliance Set thermostat to desired setting The appliance will operate The igniter will spark after the pre purge time delay 15 seconds The main valve should open System will try for ignition up to four times one time on optional single try ignition mod ule If flame is not sensed lockout will commence If the appliance will not operate follow the instruc tions To Turn Off Gas To Appliance and call your service technician or gas supplier If boiler fails to start verify the following There are no loose connections or that the service switch is off a b High temperature limit switch or manual reset high limit is not tripped c Thermostat is set above water temperature Gas is on at the meter and the boiler Incoming dynamic gas pressure to the gas valve is NOT less than 4 0 in WC for natural gas or propane gas Turn Off Gas To Appliance 1 Shut off manual gas valve field installed near gas inlet connection on back of boiler Set the thermostat to lowest setting Turn off all electrical power
88. oyed to maintain clearances and to prevent physi cal damage or separation of joints NOTE A vent adapter field supplied may be re quired to connect the Category IV vent to the boiler Termination The vent terminal should be vertical and should termi nate outside the building at least 2 ft above the highest point of the roof that is within 10 ft The vent cap should have a minimum clearance of 4 ft horizontally from and in no case above or below unless a 4 ft hori zontal distance is maintained electric meters gas meters regulators and relief equipment The distance of the vent terminal from adjacent public walkways adjacent buildings open windows and building openings must be consistent with the NFGC U S or B149 Canada Vents supported only by flashing and extending above the roof more than 5 ft should be securely guyed or braced to withstand snow and wind loads 10 OR LESS VENT PIPE HEATER UNIT CONDENSATE TRAP Fig 20 Vertical Venting NOTE When using PVC vent termination insert the round stainless mesh screens provided with the unit into the tee and terminals CAUTION A listed vent cap terminal suitable for connection to the Cat IV vent materials adequately sized must be used to evacuate the flue products from the boilers Common Venting The NFGC does not address sizing guidelines for the common venting of multiple Category IV heaters This is covered in th
89. quality and durability of our equipment Product Receipt WARNING Pump motors should NOT be supported by any type of stand or support from above due to possible misalignment of pump and motor which may occur On receipt of your heater it is suggested that you visu ally check for external damage to the shipping crate If the crate is damaged make a note to that effect on the Bill of Lading when signing for the shipment Next remove the heater from the shipping packaging Report any damage to the carrier immediately On occasion items are shipped loose Be sure that you receive the correct number of packages as indi cated on the Bill of Lading Claims for shortages and damages must be filed with the carrier by consignee Permission to return goods must be received from the factory prior to shipping Goods returned to the factory without an authorized Returned Goods Receipt number will not be accepted All returned goods are subject to a restocking charge When ordering parts you must specify the model and serial number of the heater When ordering under war ranty conditions you must also specify the date of installation Purchased parts are subject to replacement only under the manufacturer s warranty Debits for defec tive replacement parts will not be accepted Parts will be replaced in kind only per Raypak s standard war ranties Model Identification The model identification number and heater serial number
90. r 1 000 BTUH 2 225 mm per kW of the total input rating of all gas utilization equipment in the con fined space but not less than 100 2 645 cm2 One opening shall commence within 12 in 305 mm of the top and one opening shall commence within 12 in 305 mm of the bottom of the enclosure The mini mum dimension of air openings shall be not less than 3 in 76 mm in any direction Air from Outdoors The confined space shall communicate with the out doors in accordance with one of the methods below The minimum dimension of air openings shall not be less than 3 in 76 mm in any direction Where ducts are used they shall be of the same cross sectional area as the net free area of the openings to which they connect 1 Two permanent openings one commencing within 12 in 305 mm of the top and one com mencing within 12 in 305 mm of the bottom of the enclosure shall be provided The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely com municate with the outdoors Where directly communicating with the out doors or where communicating to the outdoors through vertical ducts each open ing shall have a minimum free area of 1 2 per 4 000 BTUH 550 mm per kW of total input rating of all equipment in the enclosure b Where communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 2 per 2 000 BTUH
91. ra tion The boiler ignites at 3000 RPM as indicated on the LCD display of the user interface This boiler is equipped with a standard four try ignition module it will try for ignition up to four times before going into lockout If the boiler is equipped with the optional single try ignition mod ule it will try for ignition one time before going into lockout Wait until the controller indicates 100 on the fir ing rate display screen This will take several minutes if step modulation is enabled Blower Check 1 Check the high and low fire fan speed on the user interface Enter the service mode by pressing the UP arrow key and ENTER MENU key simultane ously for 1 second Verify that the min and max fan speeds match Table R on the following page Note the high fire air intake pressure on the filter box and compare to Table Q Excessively high pressures indicate an obstruction in the air intake or undersized too long air intake ducting With a clean air filter in place record the intake air pres sure setting on the start up checklist Replace the filter when the intake air pressure increases by 0 5 WC from the reading recorded on the start up checklist The desired combustion CO2 is between 8 5 and 9 0 for natural gas and 9 0 and 9 5 for propane with CO less than 150 ppm Combustion should be checked at high and low fire Max and Min fan speed by using the service mode Enter the service mode by pressing
92. reeze Protection NOTE The vent cap must be furnished by the boiler manufacturer in accordance with its listing sales order option D 11 NOTE Condensate can freeze on the vent terminal Frozen condensate on the vent terminal can result in a blocked flue condition The stainless steel flue direct vent cap must be fur nished by the boiler manufacturer in accordance with its listing sales order option D 15 Outdoor Installation Outdoor models must be vented with listed vent mate rial per the following instructions and installed with the optional factory supplied outdoor vent kit A special vent terminal is provided in accordance with CSA requirements These must be installed as illustrated in Fig 25 Care must be taken when locating the unit outdoors because the flue gases discharged from the vent cap can condense as they leave the cap Improper location can result in damage to adjacent structures or building finish For maximum efficiency and safety the follow ing precautions must be observed 1 Outdoor models must be installed outdoors and must use the outdoor vent cap available from the manufacturer sales order option D 11 Periodically check venting system The unit s venting areas must never be obstructed in any way and minimum clearances must be observed to prevent restriction of combustion and ventilation air Keep area clear and free of combustible and flammable materials Do not locate adjacent to an
93. ssible from the front of the boiler to reset the gas pressure switch as necessary If the gas pressure regulator in the valve fails the high gas pressure switch automatically shuts down the burner Operation of either the High or Low Gas Pressure Switch will turn on an LED inside the switch housing Push the top of the plastic switch housing as shown in Fig 29 to reset a tripped pressure switch The LED will go out when the switch is reset Fig 29 High Low Gas Pressure Switch Blocked Vent Switch This heater is equipped with a blocked vent pressure switch to prevent the operation of the boiler when too much of the vent is blocked This switch is located on the left side of the heater near the left rear corner Fig 30 Blocked Vent Switch Blocked Condensate Drain Sensor This boiler is equipped with a condensate sensor to prevent operation when the condensate water level is too high The boiler shutting down from the conden sate sensor is indicative of a blocked drain or problem with the condensate management system The con densate sensor is located inside the condensate reservoir at the rear of the boiler Fig 31 Condensate Drain Sensor Operating Instructions Remove the front door If you smell gas STOP Follow listed safety instructions If you do not smell gas fol low the next steps 1 Turn on all electric power to appliance 2 Adjust the temperature setpoint of the XFyre as desired The factory
94. ssure in WC Model No Propane Gas _ DW tow eh tow NOTE Manifold pressures should be 0 3 in WC Table I Manifold Gas Pressure Settings 1 Model 3 4 NPT 1 1 4 NPT 1 1 2 NPT 2 NPT o ars woo _ me eoe pe 99 8 l9 Natural Gas 1 000 BTU ft3 0 60 specific gravity at 0 5 WC pressure drop Propane Gas 2 500 BTU ft 1 53 specific gravity at 0 6 WC pressure drop Table J Maximum Equivalent Pipe Length Electrical Power Connections Installations must follow these codes National Electrical Code and any other national state provincial or local codes or regulations hav ing jurisdiction Safety wiring must be NEC Class 1 Heater must be electrically grounded as required by the NEC In Canada CSA C22 1 C E C Part 1 The XFyre 300 850 heaters are wired for 120 V sin gle phase 60 Hz power Consult the wiring diagram shipped with the heater Before starting the heater check to ensure proper voltage to the heater and pump s A larger circuit breaker may be needed for pumps larger than 1 4 hp Boiler pumps up to 1 hp and DHW pumps up to 1 4 hp get their power supply directly from the heater power supply connections in rear wiring box XFyre heaters No m ALARM COM 10 9 PUMP NEUT B MAX 120V DHW PUMP HOT
95. st and contact with skin and eyes Use NIOSH certified dust respirator N95 This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written Other types of respirators may be needed depending on the job site conditions Current NIOSH recommendations can be found on the NIOSH website at http www cdc gov niosh homepage html NIOSH approved respirators manufacturers and phone numbers are also listed on this website Wear long sleeved loose fitting clothing gloves and eye protection Apply enough water to the combustion chamber lining to prevent dust Wash potentially contaminated clothes separately from other clothing Rinse clothes washer thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air 51 Combustion Chamber Coil Cleaning Instructions Before beginning this procedure you must have on hand the following items a nylon stainless steel or brass brush not steel Rydlyme recommended for best results or CLR Gloves eye protection 1 Shut down the XFyre boiler by using the following steps a Close the gas valve shut down the unit and wait for the unit to be cool to the touch b Disconnect the condensate piping from the out side connection not from the XFyre boiler side so the flow from condensate reservoir can be observed c Disconnect electrical connections from the gas valve spark
96. that all joints are sealed properly and are airtight The vent must be installed to prevent the potential accumulation of condensate in the vent pipes It is required that 1 The vent must be installed with condensate drains as directed by the vent manufacturer 2 The vent must be installed with a slight upward slope of not less than 1 4 inch per foot of horizon tal run to the vent terminal Termination The vent cap MUST be mounted on the exterior of the building The vent cap cannot be installed in a well or below grade The vent cap must be installed at least 1 ft above ground level and above normal snow levels Only Raypak approved vent caps may be used The vent terminal must be located NO CLOSER than 12 off the wall WARNING No substitutions of flue pipe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Model No 2313 Approved Intakes Approved Plastic Approved SS Terminals Terminals PVC 90 Elbow Sch 40 Galvanized 90 Elbow SS 90 Elbow Must be ULC S636 materials in Canada 6 PVC Tee Sch 4 PVC Tee Sch FasNSeal FSTT4 Z Vent 2SVSTTF04 FasNSeal FSTT6 Heat Fab 9690TEE 40 40 Table N Horizontal Vent and Air Intake Terminals Vent and Intake Air Vent Size in Certified Vent Material Model No Subtract 10 ft per elbow Max 4 elbows Canada Only ULC S636 PVC and CPVC Stainless Steel AL29 4C ANSI ASTM D
97. the likelihood of condensate production in the vent Category A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that avoids excessive condensate pro duction in the vent 23 Category 11 A heater which operates with a non pos itive vent static pressure and with a vent gas temperature that may cause excessive condensate production in the vent Category A heater which operates with a positive vent pressure and with a vent gas temperature that avoids excessive condensate production in the vent Category IV A heater which operates with a positive vent pressure and with a vent gas temperature that may cause excessive condensate production in the vent See Table K for appliance category requirements NOTE For additional information on appliance categorization see the ANSI Z21 13 Standard and the NFGC U S or B149 Canada or applicable provisions of local building codes CAUTION Condensate drains for the vent piping are required for installations of the XFyre Follow vent manufacturer instructions for installation and location of condensate drains in the vent Condensate drain traps must be primed with water to prevent gas flue leak and must be routed to an appropriate container for neutralization before dis posal as required by local codes WARNING Contact the manufacturer of the vent material if there is any question about the appliance categoriz
98. vels should always be taken at the highest and low est fan speed After 10 minutes the service mode stops automatically To exit the service mode press the UP and DOWN arrow keys together for 1 second Status Menu 1 Items Screen No Default Information Displayed Range Description 1 Supply XXX F 13 248 F Heater outlet water temperature Return XXX F 13 248 F Heater inlet water temperature 2 CH Set 160 F 50 190 F Heater outlet water setpoint for hydronic heating Supply XXX F 13 248 F Heater outlet water temperature Cas Set 160 F 50 190 F Cascade System sensor setpoint if Master System XXX F 13 248 F System sensor temperature if Master and present 4 DHW Set 140 F 95 180 F DHW Tank setpoint DHW XXX 13 248 F DHW tank temperature if sensor is present 5 Outdoor XXX 40 248 Outdoor air temperature if sensor is present otherwise off 6 Flame 0 0 uA Flame ionization signal Fan Speed 0 RPM Fan RPM 7 0 10V 10 0 V Remote setpoint or modulation signal 8 Bus Comm No Conn Conn No Conn Cascade bus connection or no connection 9 Power On Oh Hours the heater has been powered CH On Oh Hours with a call for heat 10 DHW On Oh Hours with a DHW demand Good ignition Ox Number of successful ignitions 11 Fault History 1 Fault type last error Last fault display code MM DD Y
99. vent tee however this can also be accomplished using an inline collec tor for condensing stacks or an inline vertical or horizontal collector available from several of the listed vent manufacturers CAUTION This venting system requires the installation of a condensate drain in the vent piping per the vent manufacturer s instructions Failure to install a condensate drain in the venting system will void all warranties on this boiler Installation These installations utilize the heater mounted blower to draw combustion air and to vent the combustion products to the outdoors The combustion air intake and the vent are installed horizontally through the wall to the outdoors Adequate ventilation air must be sup plied to the equipment room in accordance with the NFGC U S or B149 Canada The total length of the horizontal through the wall direct vent system should not exceed 200 equivalent ft in length If combined vent intake run exceeds 200 equivalent ft an appropriately sized variable speed extractor must be used Each elbow used is equal to 10 ft of straight pipe with a maximum of 4 elbows each on the air intake and vent The vent and air intake runs should be balanced to provide approximately the same equivalent length The vent cap and air intake elbow are not considered in the overall length of the venting system The vent must be installed to prevent flue gas leakage Care must be taken during assembly to ensure
100. xcessive heat Repair as nec essary Push red reset button on flue temperature switch located on the flue inside the rear access door of the boiler NOTE Switch temperature must be less than 90 F to reset Run the boiler and check the flue tem perature If the flue temperature is within specs and the switch trips replace the switch If the flue temperature is excessive check and adjust combustion controls on the boiler If problem persists inspect the target wall in the combustion chamber and replace it if cracked or damaged 1 Check the electrical connection to the thermistor on the outlet manifold Verify 5 VDC by checking in Molex connector If no 5 VDC check harness If harness is OK replace control Press the reset button on the front panel of the boiler to reset the boiler control Verify thermistor values by referencing chart on page 48 2 Replace thermistor if necessary 1 Check the electrical connection to the thermistor on the inlet manifold Verify 5 VDC by checking in Molex connector If no 5 VDC check harness If harness is OK replace control Press the reset button on the front panel of the boiler to reset the boiler control Verify thermistor values by referencing chart on page 48 2 Replace thermistor if necessary 1 Check circulation pump operation 2 Ensure that there is adequate flow through the boiler by accessing the status menu and assuring that there is less than a 50 F rise from the return thermistor to the supp
101. y window door walk way or gravity air intake The vent must be located a minimum of 4 ft horizontally from such areas Install above grade level and above normal snow levels 31 ENT ERMINAL Ax Approved Plastic Terminals Approved SS Terminals FasNSeal FSTTA Z Vent 2SVSTTF04 FasNSeal FSTT6 Heat Fab 9690TEE Must be ULC S636 materials in Canada Table P Outdoor Vent Terminals The Raypak electronic temperature control includes a freeze protection feature In the event the temperature drops below 40 F at any of the temperature sensors the pump is turned on and will remain on until the tem peratures at all sensors rise to 45 F Controls WARNING Installation adjustment and service of controls including timing of various operating func tions must be performed by a qualified installer service agency or the gas supplier Failure to do so may result in control damage malfunction property damage personal injury or death WARNING Turn off the power to the boiler before installation adjustment or service of any controls Failure to do so may result in board damage malfunction property damage personal injury or death CAUTION This appliance has provisions to be connected to more than one supply source To reduce the risk of electric shock disconnect all such connections before servicing CAUTION Risk of electric shock More than one disconnect switch may be required to de
102. ystem or drain as required by local codes 3 Check that area is free from combustible materi als gasoline and other flammable vapors and liquids 4 Check for and remove any obstruction to the flow of combustion or ventilation air to boiler 5 Follow pre start up check in the Start up section 6 Visually inspect burner flame It should be light blue at full input Remove and visually inspect direct spark igniter and sensor for damage crack ing or debris build up 7 Check operation of safety devices Refer to manu facturers instructions 8 Follow oil lubricating instructions on pump if re quired Over oiling will damage pump Water lubricated circulators do not need oiling 9 To avoid potential of severe burn DO NOT REST HANDS ON OR GRASP PIPES Use a light touch return piping will heat up quickly 10 Check blower and blower motor 11 Check for piping leaks around pumps relief valves and other fittings Repair if found DO NOT use petroleum based stop leak Periodically 1 Check relief valve Refer to manufacturer s instructions on valve 2 Testlow water cut off if equipped Refer to manu facturer s instructions Preventive Maintenance Schedule The following procedures are recommended and are good practice for all XFyre installations Daily 1 Check gauges monitors and indicators 2 Check instrument and equipment settings See Post Start Up Check 3 Check burner fla

Raypak 850 Electric Heater User Manual

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